Benelli ZAFFERAN 250 - Failure Diagnosis; Startup Motor

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3.2 Failure diagnosis
Startup failure
Weak rotation
of the starter motor
No rotation of RE rotary
engine of the starter motor
• Fuse blown
• Low battery
• Poor startup clutch
• Low battery
• Poor wiring contact
• Reversal rotation of the startup motor
• Poor main switch
• Gear seized
• Low battery
• Poor starter clutch
• Poor brake switch
• Poor starter relay
• Poor wiring contact
• Poor starter motor
3.3 Starter motor
3.3.1 Disassembly
* Note
Before the starter motor is
disassembled, turn off the main
switch, remove the GND wire of the
battery, and then power on to check
whether the starter motor works to
ensure your safety.
commutator
Remove the wire connector for the starter motor.
Remove the fixing bolts, separate the front and rear
end caps, and dismantle the starter motor.
Roll the waterproof rubber case and dismantle the
terminal of the starter motor.
3.3.2 Breakdown
Remove screws in the shell, front cover, motor
housing and other parts.
Check other components:
Replace any part with abraded, damaged or burnt
surfaces. Clean the commutator surface if there is
metal powder attached to it. Check conduction
between the surface of the other components. Ensure
non-conduction between armature shafts of the
commutator. Check the conduction of the shell of the
starter motor.
Ensure non-conduction between the conduction
terminal and the startup motor shell.
Check conduction between the conduction terminal and
the brush.
Replace any abnormal part/s.
Check conduction of the brush bracket. Replace it when
there is conduction. Measure the length of the brush.
Limit for use: replace it if lower than 8.5mm
carbon brush
Check smooth rotation of the needle bearing inside the front cover and whether it is loose when press-
ing. Replace it if there is any abnormality. Check whether the oil seal is abraded or damaged.