3 -
Electric starting system
 Notes
The references of the elements shown below are to be found in the “Wiring diagram”, Section P 1.
Electric starting system
The key components of the electric starting system are a contactor (1) and a starter motor (2) fed by the battery (3).
The engine starting strategy is managed entirely by the engine ECU (4), which monitors the following inputs:
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Engine Stop button (5)
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Engine start button (6)
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Neutral sensor (7)
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Sidestand sensor (8)
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Clutch microswitch (9).
 
When these inputs are combined in the required manner, the engine control unit (4) enables engine starting.
The table lists possible engine starting combinations.
 
In accordance with the status of specific engine control unit inputs and the indications given in the table, the control unit enables operation of the starter motor (ON status) when the START button is pressed.
X = generic status of neutral sensor, clutch, and sidestand.
Safety device functions table
Starter motor
Power: 0.7 kW/12 V.
Direction of rotation: counterclockwise viewed from power take-off side.
The starter motor is highly compact and reliable and therefore rarely gives any type of problem. In case of malfunction, ensure that the starter motor wiring terminal is properly tightened under the nut and shows no sign of corrosion. If the terminal is properly tightened and free from corrosion, remove the starter motor and test it under no-load conditions (no load applied to the shaft). Secure the starter motor to a test bench, making sure you do not damage the casing. Use a fully charged 12 V battery for the test. Use battery-motor connection cables which are no longer than 70 cm and with the same cross-section as the cable on the motorcycle itself. Connect the negative terminal of the battery to an unpainted area of the starter motor casing and the positive terminal to its electrical terminal. The shaft of the starter motor should rotate freely and at high speed. Take care not to short-circuit the two cables connected to the battery.
Removal of the starter motor
 
Operation
Section reference
Drain the engine oil
D 4, Changing the engine oil and filter cartridge
Remove the gearchange control
F 5, Removal of the gearchange control
Remove the clutch slave cylinder
F 2, Removal of the clutch slave cylinder
Remove the LH footrest
H 4, Removal of the footrest brackets
Remove the front sprocket cover
G 8, Removal of the front sprocket
Remove the alternator-side crankcase cover
N 8, Removal of the alternator-side crankcase cover
Remove the timing gears and the starter idler gear
N 9.1, Removal of the starter motor idler gear
Disconnect the starter motor/starter contactor cable (3) (see plates in the chapter “Routing of wiring on frame”, Section P 1).
Unscrew the retaining bolts (1).
 Notes
The starter motor retaining bolts are assembled with threadlocker.
 
Slide out the starter motor and gasket (2).
Refitting the starter motor
Inspect the condition of the gasket (2) and renew if necessary. Locate the gasket (2) and the starter motor on the crankcase and tighten the bolts (1) to the specified torque (Sect. C 3, Engine torque settings.
Connect the starter motor/contactor cable (3).
 Important
Fill the cap with protective grease before fitting it on the starter motor
 
Operation
Section reference
Refit the timing gears and the starter idler gear
N 9.1, Refitting the starter motor idler gear
Refit the alternator-side crankcase cover
N 8, Refitting the alternator-side crankcase cover
Refit the sprocket cover
G 8, Refitting the front sprocket
Refit the LH footrest
H 4, Refitting the footrest brackets
Refit the clutch slave cylinder
F 2, Refitting the clutch slave cylinder
Refit the gearchange control
F 5, Refitting the gearchange control
Fill the engine with oil
D 4, Changing the engine oil and filter cartridge
Starter contactor
 
Operation
Section reference
Remove the seat
E 3, Removal of the seat
The contactor (1) is fixed to the fuel tank.
Disconnect the battery (Sect. P 2, Battery).
Disconnect the wiring connector (2) of the starter contactor from the wiring harness.
Remove the protective caps (A).
If necessary, remove the contactor from its seating.
Unscrew the nuts (3), taking care to recover the spring washers (4).
Remove the starter motor-contactor cable (5).
Remove the contactor-battery cable (6).
Checking operation of the starter contactor
Apply 12 V (battery voltage) across the positive terminal (A) and negative terminal (B) of the connector.
With a multimeter connected between the two terminals (threaded studs (+) and (-)) of the contactor, check for electrical continuity (Sect. P 9, Diagnostic instruments). If there is no electrical continuity, renew the contactor.
Connect the wires (5) e (6) to the contactor terminals.
 
On refitting, ensure that terminals (+) and (-) are not oxidized; apply water repellent spray.
Tighten the nuts (3) to the specified torque (Sect. C 3, Engine torque settings).
Reconnect the wiring connector (2) to the wiring loom (Sect. P 1, Routing of wiring on frame).
Refit the cover.
Insert the contactor in its seat on the fuel tank: the contactor must be inserted fully home, i.e. until the four retaining teeth of the support bracket protrude on the contactor side.