Yamaha XMAX YP125R - Service manual > Electric starter (YP250R)

Removing the starter motor
Removing the starter motor

Disassembling the starter motor
Disassembling the starter motor

Checking the starter motor

1. Check:

Dirt → Clean with 600 grit sandpaper.

2. Measure:

Out of specification → Replace the starter motor.

Limit 22.4 mm (0.88 in)

Checking the starter motor

3. Measure:

Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

Mica undercut (depth) 1.00 mm (0.04 in)

TIP

The mica of the commutator must be undercut to ensure proper operation of the commutator.

Checking the starter motor

4. Measure:

a. Measure the armature assembly resistances with the digital circuit tester.

Digital circuit tester 90890-03174

Model 88 Multimeter with tachometer YU-A1927

Armature coil

Commutator resistance "1" Continuity (0.0100-0.0140 Ω at 20 ºC (68 ºF))

Insulation resistance "2" No continuity (Above 1 MΩ at 20 ºC (68 ºF))

Checking the starter motor

b. If any resistance is out of specification, replace the starter motor.

5. Measure:

Out of specification → Replace the brushes as a set.

Limit 3.00 mm (0.12 in)

Checking the starter motor

6. Measure:

Out of specification → Replace the brush springs as a set.

Brush spring force 7.75 N (790 gf, 27.90 oz)

Checking the starter motor

7. Check:

Damage/wear → Replace the gear.

8. Check:

Damage/wear → Replace the bearing.

Assembling the starter motor

1. Install:

TIP

Align the match marks "a" on the starter motor yoke with the match marks "b" on the starter motor front and rear covers.

Assembling the starter motor

See also:

 Yamaha XMAX YP125R - Service manual > Starter clutch and generator (YP250R)

Removing the generator cover and stator coil Removing the generator rotor and starter clutch

 Yamaha XMAX YP125R - Service manual > Oil pump (YP250R)

Removing the oil pump Removing the oil pump

Maxi Scooters: