16. STARTING SYSTEM SUPER8 125 Commutator 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 Front Cover dust seal lip. Tab Groove O-ring 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. When assembling the front cover and motor case, slightly press down the armature shaft to assemble them. Motor Case Starter Relay STARTER RELAY INSPECTION Remove the frame body cover. 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 · Inspect the starter relay operation Green/Yellow Wire STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand. Measure the voltage between the starter relay connector green/yellow wire (-) and engine ground. Turn the ignition switch ON and the battery voltage should be normal when the brake lever is fully applied. If the battery has no voltage, inspect the stop switch continuity and cable. 16-4