Kymco Agility 50 - Service manual > Starter motor

REMOVAL

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.

Remove the mrt-in box.

Remove the starter motor cable.

Remove the two starter motor mounting bolts and the motor.

Remove the waterproof rubber jacket and disconnect the starter motor cable connector.

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.

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 and there should be continuity.

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.

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.

• 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.

Install a new O-ring to the front cover.

Install the starter motor case, aligning the tab on the motor case with the tab on the front cover.

Tighten the starter motor case screws.

When assembling the front cover and motor case, slightly press down the armature shaft to assemble them.

See also: