Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 24

14. Before riveting the cover in place, check the ignition
timing as described in Chapter Three.

CAUTION

Be sure to use the correct rivets when install-
ing the inner and outer covers. These are tim-
ing cover rivets which do not have ends that
will fall into the timing compartment and
damage the ignition components.

15. Rivet the outer cover to the inner cover. Only use origi-
nal equipment rivets (part No. 8699) to secure the outer
cover. See Figure 51 and Figure 43.

Inspection

1. If necessary, refer to Chapter Two for troubleshooting.
2. Check the ignition compartment for oil leaks. If present,
remove the gearcase oil seal (B, Figure 50) by prying it out
with a screwdriver or seal remover. Install a new seal by
tapping it in place with a suitable size socket placed on the
outside of the seal. Drive the seal into position so it is flush
with the seal bore surface. If the gearcase oil seal is not
seated properly, it will leak.

Ignition Module
Removal/Installation

The ignition module (Figure 52) is mounted on the left

side of the motorcycle to the rear of the battery.
1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the ignition module cover.
3A. On 1986-1994 models, disconnect the ignition module
wires from the ignition coil. Remove the ground wire con-
nection at the frame.
3B. On 1995-1997 models, disconnect the igntion module
connector from the wiring harness.
4. Remove the ignition module assembly (Figure 52).
5. Install by reversing the preceding steps. On 1995-1997
models, tighten the ignition module bolts to 15-20 in.-lb.
(1.5-2 N•m).

ELECTRICAL SYSTEM

411

12

48

49

50

51

Incorrect

Correct

52

Vacuum-Operated Electric Switch (VOES)

Refer to Figure 53.

Removal/installation (1986-1993 models)

1. Remove the air filter backplate as described in Chapter
Ten or Chapter Eleven.
2. Remove the rear fuel tank mounting bolt.
3. Raise the rear of the fuel tank and disconnect the VOES
wire from the ignition module. Remove the VOES cable
strap.
4. Disconnect the vacuum hose from the VOES.
5. Remove the VOES ground wire bolt, washers and
locknut.
6. Remove the VOES mounting bracket fastener and re-
move the VOES from the top center engine mount bracket.

CAUTION

Make sure the VOES and its ground wire do
not contact the engine rocker box. Engine vi-
bration and heat can damage the switch
and/or ground wire.

7. Install by reversing the preceding steps while noting the
following:

a. On 1986-1990 models, tighten the VOES mounting

bracket bolt to 20 ft.-lb. (27 N•m).

b. On 1991-1993 models, tighten the VOES mounting

bracket locknut to 60-144 in.-lb. (7-16 N•m).

c. On 1986-1993 models, tighten the VOES ground

wire bolt and locknut to 25-30 ft.-lb. (34-41 N•m).

Removal/installation (1994-1997 models)

1. Remove the air filter backplate as described in Chapter
Eleven.
2. Remove the rear fuel tank mounting bolt.
3. Raise the rear of the fuel tank and push the two-pin
Deutsch connector mounted on the top motor mount rear-
ward to unsnap it from the T-stud clip.
4. Disconnect the 2-pin Deutsch connectors.
5. Remove the rubber cap mounted on the stud at the back
of the top center engine mount. Loosen, then remove the
locknut to free the VOES mounting bracket.

CAUTION

Make sure the VOES and its ground wire do
not contact the engine rocker box. Engine vi-
bration and heat can damage the switch
and/or ground wire.

6. Pull the VOES out and disconnect the vacuum hose
from the VOES.
7. Install by reversing the preceding steps while tightening
the VOES mounting bracket locknut to 60-144 in.-lb. (7-16
N•m).

Bench test

NOTE

The VOES can be tested with a timing light
while mounted on the motorcycle. Refer to

Ig-

nition Timing Adjustment

in Chapter Three.

1. Remove the VOES as described in this section.
2. Connect an ohmmeter to the two VOES electrical leads
(1986-1993) or socket terminals (1994-1997).
3. Connect a hand-operated vacuum pump to the VOES
vacuum fitting.
4. Slowly operate the vacuum pump handle while reading
the vacuum gauge and ohmmeter. The ohmmeter should
read 0 ohms with a vacuum reading of 3.5-4.5 in./Hg
(89-114 mm/Hg).
5. If the vacuum reading falls outside the specified range
when the ohmmeter reads 0 ohms, the VOES switch is
faulty and must be replaced.

IGNITION SYSTEM (ALL 1998-2003 MODELS,

EXCEPT 1200S MODELS)

The ignition system consists of a single ignition coil, two

spark plugs, ignition module, a vacuum operated electric
switch (VOES), a bank angle sensor and the rotor. This sys-
tem has an electronically controlled advance. The solid-state

412

CHAPTER TWELVE

53

VACUUM-OPERATED

ELECTRIC SWITCH (VOES)

1. Bolt (1986-1991 models)
2. Washer

(1986-1991 models)

3. Locknut

(1992-1993 models)

4. VOES
5. Top center

engine bracket

6. Locknut

(1986-1991 models)

7. Bolt

(1986-1991 models)

8. Washer
9. Ground wire

(1986-1993 models)

10. Lockwasher
11. Bolt

(1992-1993 models)

ignition control module is mounted in the gearcase cover.
The cam position sensor and timing plate are integral parts of
the ignition module. The ignition module controls the igni-
tion timing advance and ignition coil dwell time, eliminating
the need for mechanical advance and routine ignition ser-
vice.

The VOES senses intake manifold vacuum at the carbu-

retor. The switch is open when the engine is in low vacuum
situations, such as acceleration and high load. The switch is
closed when engine vacuum is high such as during a low
engine load condition. The VOES allows the ignition sys-
tem to follow two spark advance curves. A maximum spark

curve can be used during a high-vacuum condition to pro-
vide improved fuel economy and performance. During low
vacuum conditions, the spark can be retarded to minimize
ignition knock and still maintain performance.

The leading and trailing edges of the two rotor slots trig-

ger the timing sensor. As engine speed increases, the con-
trol module advances the timing in three stages.

The bank angle sensor is a normally-closed magnetic

switch. It is secured to the side of the battery tray. If the mo-
torcycle lean angle exceeds 55

°

, the sensor opens the cir-

cuit. The ignition module detects this open circuit and turns
off the ignition system. Once the sensor is activated, the
motorcycle must be returned to vertical and the ignition
turned off then on. Then, the ignition system is operational
and the engine can be restarted.

Refer to Figure 54.

Ignition Module Removal/Installation

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

The ignition module terminal pins must be re-
moved from the ignition module connector
prior to removing the wiring through the
gearcase cover.

2. Disconnect the ignition module connector (Figure 55)
from the wiring harness. Remove the terminal pins from the
connector as follows:

a. Record the position of each ignition module wiring

terminal in the end of the connector.

b. Remove the terminals from the end of the connector

as described in

Electrical Connector

in this chapter.

3. Drill out the outer cover rivets using a 3/8 in. drill bit.

4. Using a punch, tap the rivets through the outer cover
(Figure 56) and remove the outer cover.

5. Using a punch, tap the rivets through the inner cover.

6. Remove the inner cover screws (Figure 57), then re-
move the cover.

ELECTRICAL SYSTEM

413

12

54

IGNITION SYSTEM

(ALL 1998-2003 MODELS,

EXCEPT 1200S)

1. Gear case cover
2. Oil seal
3. Rotor
4. Bolt
5. Ignition module
6. Adjusting notch
7. Ignition plate screw

8. Inner cover
9. Screw

10. Outer cover
11. Rivet
12. VOES
13. Bank angle

sensor

55

56

7. To help approximate ignition timing when installing the
ignition module, mark the position of the mounting screws
on the ignition module timing plate.

8. Remove the screws (Figure 58) securing the ignition
module to the crankcase and pull the ignition module out of
the gearcase cover.

9. Note the routing of the wires. Withdraw the ignition
module wiring through the crankcase hole and remove the
module.

10. Remove the rotor bolt (A, Figure 59) and rotor (B).

11. To install the rotor:

a. Align the tab on the back of the rotor (Figure 60)

with the notch in the end of the crankshaft (A, Figure
61).

b. Apply threadlock (Loctite 242 or equivalent) to the

rotor bolt (A, Figure 59) and tighten it to 43-53
in.-lb. (5-6 N•m).

CAUTION

Route the ignition module wires approxi-
mately 1 1/2 in. (38 mm) forward of the
gearcase rear edge. Wires routed farther to
the rear may allow the wiring harness to con-
tact the secondary drive chain/belt and or
sprocket, damaging the wiring harness.

12. Insert the ignition module wires through the gearcase
cover and route the wiring harness along the noted during
removal path.

13. Before riveting the cover in place, check the ignition
timing as described in Chapter Three.

CAUTION

Be sure to use the correct rivets to install the
outer cover to the inner cover. These are tim-
ing cover rivets that do not have ends that will
fall into the timing compartment and damage
the ignition components.

14. Rivet the outer cover to the inner cover. Use only origi-
nal equipment rivets (part No. 8699) to secure the outer
cover. See Figure 62.

Inspection

1. If necessary, refer to Chapter Two for troubleshooting.

2. Check the ignition compartment for oil leaks. If present,
remove the gearcase seal (B, Figure 61) by prying it out
with a screwdriver or seal remover. Install a new seal by
tapping it in place with a suitable size driver placed on the
outside of the seal. Drive the seal in position so it is flush
with the seal bore surface. If the gearcase oil seal is not
seated properly, it will leak.

Vacuum-Operated Electric Switch (VOES)

For service information concerning bench testing and re-

placement of the VOES refer to 1994-1997 model informa-
tion in

Ignition System (1986-1997 Models)

in this chapter.

IGNITION SYSTEM

(1998-2003 1200S MODELS)

The ignition system consists of a single ignition coil, four

spark plugs, inductive pickup unit, ignition control module,
a manifold absolute pressure (MAP) sensor and bank angle
sensor. The inductive pickup unit is driven by the engine
and generates pulses, which are routed to the solid-state ig-

414

CHAPTER TWELVE

57

58

59

nition control module. This ignition module, which is
mounted under the seat, determines the ignition timing ad-
vance and ignition coil dwell time, eliminating the need for
mechanical advance and routine ignition service.

The MAP sensor is mounted on the frame backbone under

the fuel tank. This sensor monitors intake manifold vacuum
and adjusts the ignition advance for maximum performance.

The timing sensor is triggered by the leading and trailing

edges of the two rotor slots. As engine speed increases, the
control module adjusts the timing in three stages of advance.

The bank angle sensor is a normally closed magnetic

switch. It is secured to the side of the battery tray. If the mo-
torcycle lean angle exceeds 55

°

, the magnet in the sensor

moves and opens the circuit. The ignition control module

detects this open circuit and turns off the ignition system.
Once the sensor is activated, the motorcycle must be re-
turned to vertical and the ignition turned off then on. Then,
the ignition system is operational and the engine can be re-
started.

The ignition system components are shown in Figure 63.

Sensor Plate Removal/Installation

Refer to Figure 63.

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

The terminal pins must be removed from sen-
sor plate connector before removing the wir-
ing through the gearcase cover.

2. Disconnect the sensor plate connector from the wiring
harness. Then remove the terminal pins from the connector
as follows:

a. Record the position of each sensor plate terminal pin

in the end of the connector.

b. Remove the terminal pins from the connector as de-

scribed in

Electrical Connector

in this chapter.

3. Drill out the outer cover rivets with a 3/8 in. drill bit.
4. Using a punch, tap the rivets through the outer cover
(Figure 56) and remove the outer cover.
5. Using a punch, tap the rivets through the inner cover.
6. Remove the inner cover screws (Figure 57) and remove
the cover.
7. To help approximate ignition timing when installing the
sensor plate, mark the position of the sensor-plate mounting
screws on the sensor plate.
8. Remove the screws (Figure 64) securing the sensor
plate to the crankcase and pull the sensor plate out of the
gearcase cover.
9. Withdraw the sensor plate wiring harness through the
crankcase hole and remove the sensor plate. Note the rout-
ing of the wires.
10. Remove the rotor bolt (A, Figure 59) and rotor (B).
11. To install the rotor:

a. Align the tab on the back of the rotor (Figure 60)

with the notch in the end of the crankshaft (A, Figure
61).

b. Apply threadlock (Loctite 242 or equivalent) to the

rotor bolt and tighten it to 43-53 in.-lb. (5-6 N•m).

CAUTION

Route the sensor plate wires approximately 1
1/2 in. (38 mm) forward of the gearcase rear
edge. Wires routed farther to the rear may al-
low the wiring harness to contact the second-
ary

drive

chain/belt

and

or

sprocket,

damaging the wiring harness.

12. Insert the sensor plate wires through the gearcase cover
and route the wiring harness along its original path.

ELECTRICAL SYSTEM

415

12

60

61

62

Incorrect

Correct

13. Before riveting the cover in place, check the ignition
timing as described in Chapter Three.

CAUTION

Be sure to use the correct rivets to install the
outer cover to the inner cover. These are spe-
cial timing cover rivets that do not have ends
that will fall into the timing compartment and
damage the ignition components.

14. Rivet the outer cover to the inner cover. Use only origi-
nal equipment rivets (part No. 8699) to secure the outer
cover. See Figure 62.

416

CHAPTER TWELVE

63

IGNITION SYSTEM

(1998-2003 1200S MODELS)

1. Rivet
2. Outer cover
3. Screw
4. Inner cover
5. Sensor plate screw
6. Adjusting notch
7. Sensor plate
8. Bolt
9. Rotor

10. Oil seal
11. Connector
12. Ignition coil
13. Spark plug wires
14. Gear case cover
15. MAP sensor
16. Spark plug
17. Ignition control module
18. Nut
19. Bank angle sensor
20. Cam position sensor

64

Inspection

1. If necessary, follow the procedures in Chapter Two to
troubleshoot the ignition system.

2. Check the ignition compartment for oil leaks. If present,
remove the gearcase seal (B, Figure 61) by prying it out
with a screwdriver or seal remover. Install a new seal by
tapping it in place with a suitable driver placed on the out-
side of the seal. Drive the seal in position so it is flush with
the seal bore surface. If the gearcase oil seal is not seated
properly, it will leak.

Ignition Control Module Removal/Installation

The ignition control module (A, Figure 65) is mounted

under the seat.
1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the seat (Chapter Seventeen).
3. Disconnect the two harness connectors (B, Figure 65)
from the ignition control module.
4. Remove the two mounting bolts (C, Figure 65) and re-
move the ignition module from the mounting bracket.
5. Install by reversing the removal steps. Tighten the igni-
tion module mounting bolts to 15-21 in.-lb. (1.7-2.4 N•m).

IGNITION COIL

CAUTION

When replacing an ignition coil, make sure
the coil is marked ELECTRONIC ADVANCE.
Installing an older type ignition coil could
damage electronic ignition components.

Ignition Coil Testing

Refer to Chapter Two.

Removal/Installation
(All Models Except 1200S Models)

The ignition coil is mounted below the fuel tank.

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

Label all wiring connectors prior to discon-
necting them.

2. Disconnect the spark plug cables (A, Figure 66) from
the ignition coil.
3. Disconnect the ring terminal wires (B, Figure 66) from
the ignition coil.
4. Remove the ignition coil mounting bolts and nutplate
(A, Figure 67) and rest the ignition coil (B) on top of the
cylinder head cover.
5. Remove the ignition coil.
6. Installation is the reverse of the preceding steps. Tighten
the coil mounting bolts to 24-72 in.-lb. (3-8 N•m).

Removal/Installation (1200S Models)

The ignition coil is mounted below the fuel tank.

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

Label all wiring connectors prior to discon-
necting them.

ELECTRICAL SYSTEM

417

12

65

66

67

2. Disconnect the four spark plug cables (A, Figure 68)
from the ignition coil.
3. Disconnect the harness connector (B, Figure 68) from
the ignition coil.
4. Remove the ignition coil mounting bolt (C, Figure 68)
and remove the coil.
5. Installation is the reverse of removal while noting the
following:

a. Tighten the coil mounting bolt to 24-72 in.-lb. (3-8

N•m).

b. Make sure each spark plug wire is connected to the

correct tower on the ignition coil. See Figure 69.

BANK ANGLE SENSOR

(1998-2003 MODELS)

Inspection

The bank angle sensor (A, Figure 70) is mounted on the

side of the battery tray.
1. Support the motorcycle in a vertical position.
2. Start the engine.
3. Set a magnet on top of the bank angle sensor.
4. The engine will stop if the sensor is operating correctly.
5. Reset the sensor by removing the magnet and turning the
ignition switch off.

Removal/Installation

1. Remove the left side cover (Chapter Seventeen).
2. Remove the mounting bolt (B, Figure 70) and remove
the sensor.
3. Disconnect the connector (C, Figure 70) from the bank
angle sensor.
4. Reverse the removal procedure to install the sensor.
Tighten the sensor mounting bolt to 15-20 in.-lb. (1.5-2 N•m).

MANIFOLD ABSOLUTE PRESSURE

(MAP) SENSOR

(1998-2003 1200S MODELS)

Removal/Installation

1. Loosen the rear mounting bolt on the fuel tank and re-
move the front fuel tank mounting bolt.
2. Pivot the tank up to access the MAP sensor.
3. Remove the vacuum hose from the MAP sensor.
4. Use a screwdriver or other tool and open the tang (A,
Figure 71). Press the sensor down to release it from the
holding bracket.
5. Disconnect the harness connector (B, Figure 71) from
the MAP sensor and remove the sensor.
6. Install the sensor by reversing the removal procedure.
Note the following:

a. Press the MAP sensor up into the holding bracket un-

til the tang closes.

418

CHAPTER TWELVE

68

69

70

71

b. Make sure to reattach the vacuum hose to the sensor.

STARTER

The starting system consists of the starter, starter gears,

solenoid and the starter button.

When the starter button is pressed, it engages the starter

solenoid switch that completes the circuit allowing electric-
ity to flow from the battery to the starter.

When servicing the starting system, refer to the wiring

diagrams located at the end of this manual.

CAUTION

Do not operate the starter for more than five
seconds at a time. Let it cool approximately
ten seconds before operating it again.

Troubleshooting

Refer to Chapter Two.

Removal

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the primary drive cover (Chapter Six or Chap-
ter Seven).
3. Remove the rear exhaust pipe (Chapter Ten or Chapter
Eleven).
4. Disconnect the positive cable and the solenoid electrical
connector from the starter (Figure 72, typical).
5. Remove the bolts and washers (Figure 73) holding the
starter to the left crankcase. Remove the starter (Figure 74)
and gasket from the right side.
6. Service the starter as described in this section.

Installation

1. Install a new gasket onto the starter.
2. Install the starter and gasket into the crankcase.
3. Install the mounting bolts (Figure 73) and washers. Tighten
the starter mounting bolts to 13-20 ft.-lb. (18-27 N•m).
4. Clean and then reconnect the electrical connectors to the
starter motor.
5. Install the primary drive cover (Chapter Six or Chapter
Seven).
6. Install the rear exhaust pipe (Chapter Ten or Chapter
Eleven).
7. Reconnect the negative battery cable as described in this
chapter.

Disassembly

NOTE

If only servicing to the starter solenoid, refer
to the

Starter Solenoid

in this chapter.

Refer to Figure 75.

1. Clean all grease, dirt and carbon from the case and end
covers.
2. Disconnect the field coil wire (Figure 76).
3. Remove the two starter housing throughbolts (Figure
77).
4. Separate the starter field and armature assembly (Figure
78) from the solenoid housing.

NOTE

The end cover screws are equipped with
O-rings.

ELECTRICAL SYSTEM

419

12

72

73

74

420

CHAPTER TWELVE

75

STARTER

1. Bolt
2. Gasket
3. Screw
4. Drive housing
5. O-ring
6. Drive assembly
7. Spring
8. Clutch shaft
9. Idler gear bearing

10. Bearing rollers (5)
11. Idler gear
12. Ball
13. Return spring
14. Solenoid housing

15. Bearing
16. Armature
17. Bearing
18. O-ring
19. Field frame
20. Brushes
21. O-ring
22. Nut
23. Brush holder
24. Brush springs
25. End cover
26. Screw
27. Throughbolt
28. Cap

76

77

5. Remove the two screws (A, Figure 79) securing the end
cover to the brush holder. Remove the end cover (B).
6. Lift the field coil brush springs out of their holders with
a small hook and remove the brushes from their holders.
7. Slide the brush holder (Figure 80) off the commutator.
8. Separate the armature (Figure 81) from the field coil as-
sembly.
9. Remove the drive housing mounting screws (Figure
82).
10. Tap the drive housing and separate it from the starter
(Figure 83).
11. Remove the ball and spring (Figure 84) from the sole-
noid housing.

ELECTRICAL SYSTEM

421

12

78

79

80

81

82

83

84

12. Remove the drive assembly (A, Figure 83), idler gear
(B) and the idler gear bearing assembly (Figure 85) from
the drive housing.

13. Carefully remove the O-ring (Figure 86) out of the
groove in the bottom of the drive housing.

14. Inspect the starter assembly as described in this
section.

Inspection

1. The starter components should be cleaned thoroughly.
Do not clean the field coils or armature in any cleaning so-
lution that could damage the insulation. Wipe these parts
off with a clean rag. Do not soak the overrunning clutch in
any cleaning solution as the chemicals could dissolve the
lubrication within the clutch.

2. Measure the length of each brush (Figure 87). If the
length is less than the minimum wear length specified in
Table 3, replace it. Replace the brushes in sets of four, even
though only one may be worn to the service limit. See Fig-
ure 88 and Figure 89.

NOTE

The field coil brushes (

Figure 88

) are sol-

dered in position. To replace, first apply heat
to the brushes soldered joint to unsolder. Re-
move the old brushes. Solder the new brushes
in place with rosin core solder–do not use
acid core solder.

3. Inspect the condition of the commutator (A, Figure 90).
The mica in the commutator should be at least 0.008 in.
(0.20 mm) undercut. If the mica undercut is less than
specified, undercut the mica to a depth of 1/32 in. (0.79
mm). When undercutting mica, each groove must form a
right angle. Do not cut the mica so that a thin edge is left
next to the commutator segment. Figure 91 shows the
proper angle. After undercutting the mica, remove burrs by
sanding the commutator lightly with crocus cloth.

4. Inspect the commutator copper bars for discoloration. If
a pair of bars is discolored, grounded armature coils are
indicated.

422

CHAPTER TWELVE

85

86

87

88

89

5. The armature can be checked for winding shorts using a
growler. Refer this test to a dealership.
6. Place the armature in a lathe or between crankshaft cen-
ters and check commutator runout with a dial indicator. If
runout exceeds 0.016 in. (0.41 mm), true the commutator in
a lathe. When truing the commutator to eliminate the
out-of-round condition, make the cuts as light as possible.
Replace the armature if the commutator outer diameter
meets, or is less, than the wear limit listed in Table 3.
7. Use an ohmmeter and check for continuity between the
commutator bars (Figure 92); there should be continuity
between pairs of bars. If there is no continuity between
pairs of bars, the armature is open. Replace the armature.
8. Connect an ohmmeter between any commutator bar and
the armature core (Figure 93); there should be no continu-
ity. If there is continuity, the armature is grounded. Replace
the armature.
9. Connect an ohmmeter between the starter cable terminal
and each field frame brush (Figure 94); there should be
continuity. If there is no continuity at either brush, the field
windings are open. Replace the field frame assembly.
10. Connect an ohmmeter between the field frame hous-
ing and each field frame brush (Figure 95); there should
be no continuity. If there is continuity at either brush, the
field windings are grounded. Replace the field frame as-
sembly.
11. Connect an ohmmeter between the brush holder plate
and each insulated brush holder (Figure 96); there should

ELECTRICAL SYSTEM

423

12

90

91

GOOD

WORN

92

93

Ohmmeter

Commutator segment

Armature core

94

Ohmmeter

Starter
terminal

Field frame

95

Ohmmeter

Field frame

be no continuity. If there is continuity at either brush holder,
the brush holder or plate is damaged. Replace the brush
holder plate.
12. Service the armature bearings as follows:

a. Check the bearings (B, Figure 90) on the armature

shaft. If worn or damaged, remove and install new
bearings with a bearing splitter and a press.

NOTE

Note that the bearings installed on the arma-
ture shaft have different part numbers. When
replacing the bearings, identify the old bear-
ings before their removal in relationship to
their position on the armature. This informa-
tion can then be used to make sure the new
bearings are installed correctly.

b. Check the bearing bores in the end cover and sole-

noid housing. Replace the cover or housing if this
area is worn or cracked.

13. The drive assembly is bolted onto the end of the sole-
noid housing. Inspect it as follows:

a. Check the teeth on the idler gear (A, Figure 85) and

drive assembly (A, Figure 97) for wear or damage.

b. Check for chipped or worn bearing rollers (B, Figure

85). Damaged rollers will cause the pinion to turn
roughly in the overrunning direction.

c. Check the idler gear shaft in the drive housing for

wear or damage.

d. Replace worn or damaged parts as required.

14. Check the pinion gear (B, Figure 97) teeth for cracks,
deep scoring or excessive wear.
15. Check the drive assembly bearings (C, Figure 97) for
wear or damage.

Assembly

Refer to Figure 75.

1. Prior to assembly, perform the procedures in

Inspection

in this section to make sure all worn or defective parts have
been repaired or replaced. Thoroughly clean all parts be-
fore assembly.
2. Apply a thin layer of water-resistant bearing lubricant
(Lubriplate 110 or equivalent) onto the drive housing
O-ring and insert the O-ring into the groove in the bottom
of the housing (Figure 86). Make sure the O-ring seats
properly in the groove.
3. After the drive assembly components have been cleaned
and dried, lubricate all components with water-resistant
bearing lubricant (Lubriplate 110 or equivalent).
4. Place the idler gear onto the shaft in the drive housing.
Then place the idler bearing cage in the gear so that the
open cage end faces toward the solenoid; see B, Figure 85.
Install the bearing pins in the cage.
5. Insert the drive assembly (A, Figure 83) into the drive
housing.

6. Drop the ball into the shaft and slide the spring (Figure
84) onto the solenoid plunger shaft.
7. Align the drive housing (A, Figure 98) with the sole-
noid housing (B) and assemble both housings. Secure the
drive housing with the screws (Figure 82). Tighten the
screws securely.

424

CHAPTER TWELVE

96

Insulated
brush
holder

Test leads

Brush holder plate

97

98

8. Pack the armature bearings with water-resistant bearing
lubricant (Lubriplate 110 or equivalent). Then install the ar-
mature (Figure 99) into the solenoid housing.

NOTE

The armature is not shown in

Figure 100

for

clarity.

9. Note the slot in the solenoid housing rim (Figure 100)
and the boss on the field frame (Figure 101). Install the
field frame around the armature and into the solenoid hous-
ing while inserting the boss into the slot.
10. Install the brush plate (Figure 102) into the end of the
frame and install the four brushes so that they ride on the
commutator.
11. Install the two positive brushes as follows:

a. The positive brushes are soldered to the field coil as-

sembly.

b. Pull a positive brush out of its brush holder. A piece

of wire bent to form a small hook on one end can be
used to access the brushes.

c. Insert the positive brush into its brush holder.
d. Release the spring so that tension is applied against

the brush.

e. Repeat for the other positive brush.

12. Install the two negative brushes as follows:

a. The negative brushes are mounted on the brush

holder.

b. Pull a negative brush out of its brush holder. A piece

of wire bent to form a small hook on one end can be
used to access the brushes.

c. Insert the negative brush into its brush holder.
d. Release the spring so that tension is applied against

the brush.

e. Repeat for the other negative brush.

13. Align the slot in the rear cover with the terminal in the
frame and install the rear cover (B, Figure 79). Install the
throughbolts (Figure 77) through the starter assembly.
Tighten the starter throughbolts to the specification listed in
Table 4.
14. Secure the brush holder to the rear cover with the two
screws (A, Figure 79) and washers. Tighten the screws se-
curely.
15. Reconnect the solenoid wire (Figure 76).

STARTER SOLENOID

Disassembly/Reassembly

Refer to Figure 103.

CAUTION

Do not tighten the inner retaining nut (

Figure

104

) unless the plunger is removed. Other-

wise, the internal contact may move and be
damaged during operation.

1. Remove the starter as described in this chapter.

ELECTRICAL SYSTEM

425

12

99

100

101

102

2. Separate the solenoid (B, Figure 98) from the starter as-
sembly as described in this chapter.
3. Remove the screws and washers holding the cover to the
solenoid housing. Then remove the cover and gasket (Fig-
ure 105).
4. Remove the solenoid plunger from the solenoid housing
(Figure 106).
5. Inspect the plunger (Figure 107) for wear or damage.
6. Inspect the solenoid housing (A, Figure 108) for wear,
cracks or other damage. The solenoid housing is only avail-
able as part of a complete solenoid unit.
7. Be sure the flat surface of each internal contact (B, Fig-
ure 108) is parallel to the end of the housing. Loosen the re-
taining nut and reposition the contact as needed.
8. Installation is the reverse of the preceding steps. Make
sure the solenoid plunger shaft engages the spring in the
drive assembly shaft.

LIGHTING SYSTEM

The lighting system consists of a headlight, tail-

light/brake light combination, turn signals, indicator lights
and meter illumination lights.

Always use the correct bulb. The manufacturer lists bulb

sizes by part number. The use of a higher wattage bulb will
provide a dim light. A lower wattage bulb will burn out pre-
maturely. Replacement bulbs can be purchased through deal-
erships by part number or by reading the number of the
defective bulb and cross-referencing it with another supplier.

Headlight Replacement

1986-1990 models

These models are equipped with a sealed beam halogen

headlight. Refer to Figure 109.

WARNING

If the headlight has just burned out or has just
been turned off, it will be hot. Do not touch
the bulb until it cools.

1. Remove the trim ring retaining screw (A, Figure 110),
then remove the trim ring (B).
2. Remove the headlight bulb from the rubber mount ring.
3. Detach the electrical connector from the bulb, then re-
move the headlight bulb.
4. Install by reversing the preceding steps while noting the
following:

a. Make sure the electrical connector is free of corro-

sion and that the wiring in the headlight housing will
not be pinched when the headlight bulb is installed.

b. Make sure the electrical connector is pushed on

tightly.

c. Check headlight operation before riding the motorcy-

cle.

426

CHAPTER TWELVE

103

STARTER SOLENOID

1. Solenoid housing
2. Plunger
3. Gasket
4. Cover
5. Bolt

104

105