18. STARTING SYSTEM
18-0
Mongoose/KXR 250
18
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STARTING SYSTEM
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SERVICE INFORMATION -------------------------------------------- 18- 2
TROUBLESHOOTING ------------------------------------------------- 18- 2
STARTER MOTOR ----------------------------------------------------- 18- 3
STARTER RELAY------------------------------------------------------ 18- 6
STARTER CLUTCH ---------------------------------------------------- 18- 7
18
18. STARTING SYSTEM
18-1
Mongoose/KXR 250
STARTING CIRCUIT
Fuse/Battery/Starter Relay
Starter Button
Starter Motor
Stop Switches
Ignition Switch
18. STARTING SYSTEM
18-2
Mongoose/KXR 250
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The removal of starter motor can be accomplished with the engine installed.
TROUBLESHOOTING
Starter motor won‘t turn Lack of power
• Fuse burned out • Weak battery
• Weak battery • Loose wire or connection
• Faulty ignition switch • Foreign matter stuck in starter motor
• Faulty starter clutch
or gear
• Faulty front or rear stop switch
• Faulty starter relay Starter motor rotates but engine does
• Poorly connected, broken or shorted wire
not start
• Faulty starter motor • Faulty starter clutch
• Faulty change gear control unit • Starter motor rotates reversely
• Weak battery
18. STARTING SYSTEM
18-3
Mongoose/KXR 250
STARTER MOTOR
REMOVAL
Remove the waterproof rubber jacket and
remove nut to disconnect the starter motor
cable connector.
Remove the two starter motor mounting
bolts and the motor.
DISASSEMBLY
Remove the two starter motor case screws,
front cover, motor case and other parts.
INSPECTION
Inspect the removed parts for wear, damage
or discoloration and replace if necessary.
Clean the commutator if there is metal
powder between the segments.
Check for continuity between pairs of the
commutator segments and there should be
continuity.
Also, make a continuity check between
individual commutator segments and the
armature shaft. There should be no
continuity.
Front Cover
Bolts
Rubber Jacket
Commutator
Before removing the starter motor, turn
the ignition switch OFF and remove the
battery ground. Then, turn on the
ignition switch and push the starter
button to see if the starter motor
operates properly.
°Ø
Motor Case
Case Screws
18. STARTING SYSTEM
18-4
Mongoose/KXR 250
STARTER MOTOR CASE
CONTINUITY CHECK
Check to confirm that there is no continuity
between the starter motor wire terminal and
the motor front cover.
Also check for the continuity between the
wire terminal and each brush.
Replace if necessary.
Measure the length of the brushes.
Service Limit: 8.5mm replace if below
Check for continuity between the brushes.
If there is continuity, replace with new
ones.
Check if the needle bearing in the front cover
turns freely and has no excessive play.
Replace if necessary.
Check the dust seal for wear or damage.
Wire Terminal
Bearing
Dust Seal
18. STARTING SYSTEM
18-5
Mongoose/KXR 250
ASSEMBLY
Apply grease to the dust seal in the front
cover.
Install the brushes onto the brush holders.
Apply a thin coat of grease to the two ends
of the armature shaft.
Insert the commutator into the front cover.
Install a new O-ring to the front cover.
Install the starter motor case, aligning the
tab on the motor case with the groove on the
front cover.
Tighten the starter motor case screws.
STARTER MOTOR INSTALLATION
Connect the starter motor cable connector
and properly install the waterproof rubber
jacket.
Check the O-ring for wear or damage and
replace if necessary.
Apply grease to the O-ring and install the
starter motor.
Tighten the two mounting bolts.
Torque: 0.8_ 1.2kgf-m
Front Cover
Groove
Commutator
Motor Case
O-ring
O-ring
Tab
• Be careful not to damage the brush and
armature shaft mating surfaces.
• When installing the commutator, the
armature shaft should not damage the
dust seal lip.
°Ø
When assembling the front cover and
motor case, slightly press down the
armature shaft to assemble them.
°Ø
The starter motor cable connector must
be installed properly.
°Ø
18. STARTING SYSTEM
18-6
Mongoose/KXR 250
STARTER RELAY
INSPECTION
Remove the seat. (Refer to the chapter 2)
Turn the ignition switch ON and the starter
relay is normal if you hear a click when the
starter button is depressed.
If there is no click sound:
• Inspect the starter relay voltage
• Inspect the starter relay ground circuit
• Check for continuity between the starter
relay yellow/red and green/red wire
terminals
STARTER RELAY VOLTAGE
INSPECTION
Connect a 12V battery across the starter
relay yellow/red and green/red wire
terminals.
Connect an electric tester between the
starter relay large terminals and check for
continuity between the two terminals.
The relay is normal if there is continuity.
Replace the starter relay with a new one if
there is no continuity.
Starter Relay
Green/Red Wire
Yellow/Red Wire
Starter Relay
18. STARTING SYSTEM
18-7
Mongoose/KXR 250
STARTER CLUTCH
REMOVAL
Remove the right crankcase cover. (Refer to
the “WATER PUMP SHAFT
REMOVAL” section in the chapter 12)
Remove the flywheel. (Refer to the “A.C.
GENERATOR/FLYWHEEL
REMOVAL” section in the chapter 16)
Inspect the starter one-way clutch for wear
or damage.
Remove the starter driven gear.
Inspect the starter driven gear for wear or
damage.
Remove the starter idle gear and shaft.
Starter Relay
Starter Driven Gear
Starter Idle Gear
Starter Idle Gear Shaft
18. STARTING SYSTEM
18-8
Mongoose/KXR 250
Inspect the starter idle gear and shaft for
wear or damage.
INSTALLATION
Reverse the “REMOVAL” procedures.
Install the starter idle gear and shaft.
Install the starter driven gear.
Install flywheel and right crankcase cover.
(Refer to the “A.C.
GENERATOR/FLYWHEEL
INSTALLATION” section in the chapter
16)
Starter Idle Gear
Starter Idle Gear Shaft
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