Bad Boy 1500 - Starting System

PAGE 129
Starting System:
Starting circuit diagram
Inspection on starter relay
• Open the main switch.
• Press the brake.
• Push down the starter
switch.
• If a sound of “CLICK”
is heard, it indicates
the relay function
normally.
• Remove the seat.
• Disconnect the negative cable terminal of the
battery.
• Disconnect the cable positive terminal from the
relay.
• Disconnect the positive cable of the starter motor.
• Disconnect the coupler of the relay.
• Connect an ohmmeter to the large terminal end.
• Connect the yellow/red cable to the battery positive
terminal and the black / blue cable to the battery
negative terminal.
• Check the continuity of the large terminal end. If
there is no continuity, replace the relay.
Removal of Starter motor:
• Remove the seat.
• Disconnect the cable negative terminal (-), then the
cable positive terminal (+).
• Remove starter motor cable.
• Loosen the lock bolts and remove the starter
motor.
Installation of Starter motor
• Install in reverse order of removal procedures.
Cooling Fan Thermo Switch:
• The thermo switch mounted on the radiator
controls the operation of the cooling fan motor.
• In case that the fan motor fails to work, disconnect
the green and black/blue leads and connect jump
wires to the terminals, then, turn on the main
switch, the fan motor should operate.
• If the fan motor still fails to run, measure battery
voltage between the green and black/blue leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit.
• If the fan motor runs, check the thermo switch in
the manner as described below:
• Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and closing
temperatures, confirm the switch is open circuited
at room temperature, increase the coolant
temperature gradually. The switch should have
continuity at 85 +/- 3°C.
CAUTION
• Keep the coolant at a constant temperature at
Least for three minutes. Sudden increase the coolant
temperature will cause the thermometer and the tester
to indicate wrong readings.
•Never let the thermometer and the thermo switch
contact the wall of the bowl, which may result in
wrong readings.
•The thermo switch shall be placed in the coolant until
the teeth are completely submerged.