Troubleshooting
Make sure that the fuses are not blown and the battery is fully-charged before diagnosing.
Starter motor will not run
Step 1
- 1) Shift the transmission to neutral.
- 2) Pull the clutch lever, turn on the ignition switch with the engine stop switch in the "RUN" position and listen for a click from the starter relay when the starter button is pushed.
Is a click sound heard?
| YES | Go to Step 2. |
| NO | Go to Step 3. |
Step 2
- 1) Check if the starter motor runs when its terminal is connected to the battery + terminal. (Do not use thin "wire" because a large amount of current flows.)
Does the starter motor run?
| YES | Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery + terminal |
| NO | Faulty starter motor |
Step 3
- 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and B/Y −) when the starter button is pushed.
Is a voltage OK?
| YES | Go to Step 4. |
| NO | Faulty engine stop switch Faulty clutch switch Faulty GP switch Faulty turn signal/side-stand relay Faulty starter button Faulty ignition switch Faulty side-stand switch Poor contact of connector Open circuit in wire harness |
Step 4
- 1) Check the starter relay.
Is the starter relay OK?
| YES | Poor contact of the starter relay |
| NO | Faulty starter relay |
Starter motor runs but does not crank the engine
Step 1
- 1) The starter motor runs when the transmission is in neutral, but does not run when the transmission is in any position other than neutral, with the side-stand up.
- 2) Check the side-stand switch.
Is the side-stand switch OK?
| YES | Go to Step 2. |
| NO | Faulty side-stand switch |
Step 2
- 1) Check the starter clutch.
Is the starter clutch OK?
| YES | Faulty starter clutch |
| NO | Open circuit in wire harness Poor contact of connector |
Starter motor removal
- Remove the right frame side cover. (9-5)
- Remove the exhaust pipe and muffler. (7-8)
- Remove the master cylinder cover 1.
- Disconnect the battery − lead wire.
- Disconnect the starter motor lead wire 2.
- Remove the starter motor 3.
Starter motor disassembly
- Disassemble the starter motor as shown in the illustration.
1. O-ring; 2. Housing end (inside); 3. Armature; 4. Starter motor case; 5. Brush holder; 6. Housing end (outside); А. Starter motor lead wire nut; В. Starter motor mounting bolt
| ITEM | Nm | kgf·m | lb·ft |
| А | 6 | 0.6 | 4.5 |
| В | 6 | 0.6 | 4.5 |
Starter motor inspection carbon brush
- Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder.
If any damages are found, replace the brush assembly with a new one.
Make sure that the length А is not less than 6.0 mm (0.24 in). If this length becomes less than 6.0 mm (0.24 in), replace the brush.
Starter motor brush length:
- Service limit: 6.0 mm (0.24 in)
Commutator
- Inspect the commutator for discoloration, abnormal wear or undercut А.
If abnormal wear is found, replace the armature with a new one. If the commutator surface is discolored, polish it with #400 sand paper and wipe it using a clean dry cloth.
If there is no undercut, scrape out the insulator with a saw blade.
1. Insulator; 2. Segment
Armature coil inspection
Check for continuity between each segment and between each segment and the armature shaft using the multi-circuit tester.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one.
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Continuity test (•)))
Bearing inspection
- Inspect the armature shaft bearing for abnormal noise and smooth rotation.
- Replace the armature assembly if there is anything unusual.
Housing end inspection
- Inspect the bearing for abnormal noise and smooth rotation.
- Check the oil seal lip for damage or leakage.
If any damage is found, replace the housing end.
Starter motor reassembly
Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points:
- Apply SUZUKI SUPER GREASE "A" to the lip of the oil seal and bearing.
- 99000-25010: SUZUKI SUPER GREASE "A" or equivalent
- Align the projection 1 on the brush holder with the groove 2 on the starter motor case.
- Tighten the brush holder nut to the specified torque.
- Brush holder nut: 10 Nm (1.0 kgf·m, 7.0 lb·ft)
- Align the projection 3 on the brush holder with the groove 4 on the housing end.
- Align the line on the starter motor case with the line А on the housing end.
- Apply a small quantity of THREAD LOCK to the starter motor housing bolts.
- 99000-32050: THREAD LOCK "1342" or equivalent
- Apply SUZUKI SUPER GREASE "A" to the O-ring.
- 99000-25010: SUZUKI SUPER GREASE "A" or equivalent
- Tighten the starter motor mounting lead wire bolts 5 and nut 6 to the specified torque.
- Starter motor mounting bolt: 6 Nm (0.6 kgf·m, 4.5 lb·ft)
- Starter motor lead wire nut: 6 Nm (0.6 kgf·m, 4.5 lb·ft)
Starter relay inspection
- Remove the front seat. (9-4)
- Remove the battery cover.
- Disconnect the battery − lead wire from the battery.
- Remove the starter relay cover 1.
- Disconnect the starter relay coupler 2, starter motor lead wire 3 and battery lead wire 4.
- Remove the starter relay.
- Apply 12 V to А and В terminals and check for continuity between the positive and negative terminals using the multi-circuit tester. If the starter relay clicks and continuity is found, the relay is ok.
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Continuity test (•)))
Caution: Do not apply battery voltage to the starter relay for more than five seconds, since the relay coil may overheat and get damaged.
Measure the relay coil resistance between the terminals using the multi-circuit tester. If the resistance is not within the specified value, replace the starter relay with a new one.
- 09900-25008: Multi-circuit tester set
- Starter relay resistance: 3 - 6 Ω
Side stand/ignition interlock system parts inspection
Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one.
Side-stand switch
- Remove the left frame side cover. (9-5)
- Disconnect the side-stand switch coupler and measure the voltage between Green and Black/White lead wires.
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Diode test (4)
| Green (+ Probe) | Black/White (− Probe) | |
| ON (Side-stand up) | 0.4 - 0.6 V | |
| OFF (Side-stand down) | 1.4 V and more (Tester's battery voltage) | |
Note: If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.
Gear position switch
- Remove the right frame side cover. (9-5)
- Disconnect the gear position switch coupler and check the continuity between Blue and Black/White with the transmission in "NEUTRAL".
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Continuity test (•)))
| Blue | Black/White | |
| ON (Neutral) | О—О | |
| OFF (Except neutral) | ||
Caution: When disconnecting and connecting the gear position switch coupler, make sure to turn OFF the ignition switch, or electronic parts may get damaged.
- Connect the gear position switch coupler to the wiring harness.
- Turn the ignition switch to "ON" position and side-stand to upright position.
- Measure the voltage between Pink and Black/White lead wires using the multi-circuit tester when shifting the gearshift lever from low to top.
- 09900-25008: Multi-circuit tester set
- 09900-25009: Needle pointed probe set
- Tester knob indication: Voltage
- Gear position switch voltage: 0.6 V and more
- Low to top gear position (Pink + - B/W −)
- Except neutral position (Pink + - B/W −)
Caution: Use the special tool, to prevent the rubber of the water proof coupler from damage.
Turn signal/side-stand relay
The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode.
- Remove the left frame side cover. (9-5)
- Remove the turn signal/side-stand relay.
Side-stand relay inspection
First check the insulation between D and E terminals with the tester. Then apply 12 V to terminals D and C (+ to D and − to C) and check the continuity between D and E. If there is no continuity, replace the turn signal/side-stand relay with a new one.
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Continuity test (•)))
| − Probe of tester to: | + Probe of tester to: | ||
| C, B | A | ||
| C, B | 1.4 V and more (Tester's battery voltage) | ||
| A | 0.4 - 0.6 V | ||
Diode inspection
Measure the voltage between the terminals using the multi-circuit tester. Refer to the following table.
- 09900-25008: Multi-circuit tester set
- Tester knob indication: Diode test
Note: If the multi-circuit tester reads 1.4 V and below when the tester probes are not connected, replace its battery.