206
AR607D
NOTE: If the meter showed correct voltage but the
starter motor did not operate or operated slowly, the
starter motor is defective.
NOTE: If the meter showed no voltage, inspect the
main fuse, ground connections, starter motor lead,
battery voltage (at the battery), starter relay, or the
neutral start relay.
REMOVING
1. Disconnect the battery.
2. Remove the nut securing the positive cable to the
starter motor; then remove the cable from the starter
motor.
3. Remove the two cap screws securing the starter
motor to the crankcase; then remove the starter
motor. Account for the wiring forms and an O-ring.
INSTALLING
1. Apply a small amount of grease to the O-ring seal on
the starter motor; then install the starter motor into
the crankcase. Secure with two machine screws and
wiring forms.
2. Secure the positive cable to the starter motor with the
nut.
3. Connect the battery (positive cable first).
Electronic Control
Module (ECM)
The electronic control module (ECM) is located beneath
the seat near the battery (500/550/700) or under the
fender near the taillight (1000).
NOTE: The ECM is not a serviceable component. If
the unit is defective, it must be replaced.
The ECM is rarely the cause for electrical problems; how-
ever, if the ECM is suspected, substitute another ECM of the
same part number to verify the suspected one is defective.
Codes can be cleared by following the procedures located
in EFI Diagnostic System in this section.
Regulator/Rectifier
The regulator/rectifier is located under the rear rack and
rear fenders.
TESTING
1. Start engine and warm up to normal operating tem-
perature; then connect a multimeter to the battery as
follows.
2. Select the DC Voltage position; then connect the red
tester lead to the positive battery post and the black
tester lead to the negative battery post.
3. Start the engine and slowly increase RPM. The volt-
age should increase with the engine RPM to a maxi-
mum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the reg-
ulator is faulty or a battery connection is loose or
corroded. Clean and tighten battery connections or
replace the regulator/rectifier. If voltage does not rise,
see Stator Coil/Crankshaft Position (CKP) Sensor -
Voltage in this section. If charging coil voltage is nor-
mal, replace the regulator/rectifier.
Headlights
The connectors are the four 2-prong ones plugged into
the headlight bulbs (two on each side).
VOLTAGE
NOTE: Perform this test in turn on the main harness
side of all four connectors. Also, the ignition switch
must be in the LIGHTS position.
NOTE: The LO beam is the outside bulb, and the HI
beam is the inside bulb.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to one wire; then connect
the black tester lead to the other wire.
3. With the dimmer switch in the LO position, test the
two outside connectors (LO beam). The meter must
show battery voltage.
4. With the dimmer switch in the HI position, test the
two inside connectors (HI beam). The meter must
show battery voltage.
CAUTION
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.
