Starter motor - GPR 125 Racing Derbi Motorcycles

It is generally possible to remove the starter motor on a 1998 Harley FXSTC (EVO) without removing the oil tank. However, it may be necessary to remove other parts or components in order to access the starter motor.
To remove the starter motor on a 1998 Harley FXSTC (EVO), you will need to follow these steps:

1. Disconnect the negative battery cable. This will prevent any electrical accidents while working on the starter motor.
2. Remove the starter motor cover, if applicable. This is typically located on the side of the engine near the starter motor.
3. Disconnect the electrical connections to the starter motor. This includes the starter solenoid wire and the starter motor wire.
4. Remove any fasteners that hold the starter motor in place. These are typically bolts or screws that hold the starter motor to the engine or frame.
5. Carefully lift the starter motor off of the motorcycle.

It's important to be careful when removing the starter motor to avoid damaging the motor or the motorcycle. If you are unsure of how to remove the starter motor or if you encounter any difficulties, it may be best to consult a mechanic or the motorcycle's service manual for further guidance.

STARTER REPLACEMENT (ENGINE ELECTRICAL) Document ID# 688149 Starter Replacement

Removal Procedure

Important: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced only as a complete unit.

1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the starter motor BAT terminal nut and electrical leads.
4. Remove the starter motor S terminal nut and electrical lead.
5. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



6. Remove the starter motor bolts.
7. Remove the starter motor.

Installation Procedure

1. Install the starter motor.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the starter motor bolts.Tighten:
   Tighten the starter motor bolts to 47 [n-m] (35 lb ft).
3. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



4. Install the starter motor S terminal electrical lead and nut. Tighten:
   Tighten the starter motor solenoid S terminal nut to 3 [n-m] (27 lb in).
   
5. Install the starter motor BAT terminal electrical leads and nut. Tighten:
   Tighten the starter motor solenoid BAT terminal nut to 10 [n-m] (89 lb in).
   
6. Lower the vehicle.
7. Install the battery ground (negative) cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.

TESTING WARNING
During the following test, the starter motor must not be energized for longer than 5 seconds, otherwise you run the risk of burning out the starter motor coil.

1. Remove the starter motor from the vehicle.
2. Detach the field coil lead from terminal M on the starter motor.
3. Using jumper wires, connect a 12 volt battery to the starter motor so that the negative battery terminal is attached to the starter motor housing and to solenoid terminal M, and that the positive battery terminal is connected to starter motor solenoid terminal S. The starter motor plunger should move outward; if it does not, replace the solenoid with a new one. Fig. 1: To test the solenoid plunger, first detach the field coil lead from alternator terminal M, then attach a 12 volt battery to the starter motor as shown . . .
   Fig. 2: . . . then detach the negative jumper wire from terminal M. The plunger should remain extended
   Fig. 3: Detach the other negative lead from the starter motor housing. The solenoid plunger should now retract to its normal resting position
   Fig. 4: Use an ammeter to measure the amount of current draw the starter motor uses
   
   
4. Detach the negative battery jumper wire from terminal M on the starter motor solenoid, and check the plunger for movement. The plunger should remain extended; if the plunger returns to its resting position, replace the solenoid with a new one.
5. While observing the solenoid plunger, detach the negative battery lead from the starter motor housing. The plunger should return to its normal resting position; if it does not, replace the solenoid with a new one.
6. Reattach the 12 volt battery and install an ammeter to the starter motor as shown in the accompanying illustration. The starter motor should rotate smoothly and steadily with the pinion gear moving out, and the ammeter should display less than 60 amps at 11.5 volts (Samurai models), or 90 amps at 11 volts (Sidekick, Tracker, X-90 and Sidekick Sport models). If the ammeter does not display the specified values, or if the starter motor does not operate smoothly and steadily, replace the starter motor with a new one.

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REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. If necessary for added under-vehicle clearance, apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle on jackstands.
3. From beneath the vehicle, label and detach all wiring from the starter motor solenoid terminals.
4. Remove one of the two starter motor mounting bolts and loosen the other bolt until it can be turned by hand, then support the starter motor with one hand while removing the last starter motor mounting bolt.
5. Lower the starter motor down and away from the engine and transmission. To install:
   
6. Hold the starter motor in position and install the two mounting bolts. Tighten the two bolts securely.
7. Reattach all applicable wiring to the starter motor solenoid. Ensure that the wiring terminals and connectors are clean and free of corrosion.
8. If necessary, lower the vehicle.
9. Connect the negative battery cable.

SOLENOID REPLACEMENT
(see Figures 5, 6 and 7)

Prior to removing the solenoid from the starter motor unit, matchmark the solenoid-to-starter motor housing position, as shown in the accompanying illustration.

1. Remove the starter motor from the vehicle.
2. Detach the solenoid-to-starter motor wire from the solenoid terminal.

Do not disassemble the solenoid; if the solenoid is defective, replace the entire unit with a new one.

1. Remove the two attaching screws, then slide the solenoid out of the starter motor housing flange.
   

Fig. 5: Before removing the starter motor solenoid, matchmark the solenoid-to-starter motor housing relationship



Fig. 6: Disconnect the field coil lead from the solenoid by loosening the retaining nut ...



Fig. 7: ... then remove the two attaching screws and separate the solenoid from the motor housing


To install:

1. Inspect the solenoid plunger joint for wear or other damage. Replace it, if damage is evident.
2. Apply Suzuki Super Grease A (99000-25010) or equivalent, to the solenoid plunger and to the tip of the lever arm (inside the starter motor-to-solenoid housing hole).
3. Insert the solenoid into the starter motor housing, ensuring that the matchmarks made during removal are aligned.
4. Install and tighten the two attaching screws securely.
5. Attach the starter motor-to-solenoid wire to the solenoid terminal.
6. While the starter motor is removed form the vehicle, perform the testing procedure to ensure that the new solenoid functions properly.
7. Install the starter motor.

Hope this help (remember rated and comment this).

Sounds like a bad connection. Clean all the connections first then if you have a clicking sound coming from the PDC (fuse box) on the drivers side under the hood then it sounds like you have a bad starter .
As the relay is clicking that means the ignition switch is good. Just insure that the relay is good. There is a spare in the PDC you can swap and check out so its the starter Starter/solenoid combo.take your volt meter and check battery volts while the starter is engaged, if you see very little change from the static voltage it's likely the starter bendix is being egaged into the ring gear but the high current side of the starter is not working, this is likely due to a dirty or worn commutator or worn brushes in the starter motor. If you do see a larger drop in voltage( say down to under 9.5volts) you more than likely have a current flow issue, possibly a weak cell in the battery, or a shorted starter motor winding.My best recomendation would be to remove the starter motor, and the battery, take them in with you to your local parts house and have them both tested, most parts stores will perform these tests for free, on the possibility that hey can sell you something.
STARTER MOTORREMOVAL:-1. Disconnect and isolate the battery negative cable.2. Raise and support the vehicle.3. Remove the nut and lock washer securing the starter motor to the mounting stud on the transmission torque converter housing Starter Motor Remove/Install4. While supporting the starter motor with one hand, use the other hand to remove the upper mounting screw from the starter motor.5. Slide the automatic transmission cooler tube bracket forward on the tubes far enough for the starter motor mounting flange to be removed from the lower mounting stud.6. Move the starter motor towards the front of the vehicle far enough for the nose of the starter pinion housing to clear the transmission torque converter housing. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.7. Tilt the nose downwards and lower the starter motor far enough to access and remove the nut that secures the battery positive cable connector eyelet to the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.8. Remove the battery positive cable connector eyelet from the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.9. Disconnect the battery positive cable wire harness connector from the solenoid terminal connector receptacle. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.10.Remove the starter motor from the engine compartment. --This will help. Thanks please keep updated.please do rate the solution positively .thank you for using fixya

2.0L DOHC Engine

1. Before servicing the vehicle, refer to the Precautions section.
   
2. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Air cleaner outlet tube
     
   • Lower starter motor bolt
     
   • Two starter motor upper bolts
     
3. Slide the starter motor from its mounting until you can gain access to the wiring.
   
   • Integral connector
     
   • Starter motor
     

To install:

1. Install or connect the following:
   
   • Integral connector and tighten the retaining nuts to 61 inch lbs. (7 Nm)
     

Starter motor to its mounting

Two starter motor upper bolts and tighten to 15–20 ft. lbs. (20–27 Nm)

Lower starter motor bolt and tighten to 15–20 ft. lbs. (20–27 Nm)

Air cleaner outlet tube

Negative battery cable

Starter - Removal & installing

1. Disconnect the negative battery cable.
2. Raise and safely support the front of the vehicle securely on jackstands.
3. Disengage the solenoid wiring connector from the terminal. This connection may be held in place by a retaining nut, or it could be a push-in connector.
4. Remove the B+ nut and wire from the starter motor terminal.
5. Remove the starter motor-to-transaxle bellhousing mounting bolts.
6. Remove the starter from the vehicle. If equipped, remove the starter motor spacer.

To install:

1. If equipped, hold the starter motor spacer in position.
2. Install the starter motor into position on the vehicle.
3. Install the starter motor-to-transaxle bellhousing mounting bolts. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
4. Engage the solenoid wiring connector onto the starter terminal.
5. Connect the B+ wire and tighten the retaining nut to 90 inch lbs. (10 Nm).
6. Lower the vehicle.
7. Connect the negative battery cable.
8. Verify starter motor operation.

Disengage the solenoid wiring connector, then the battery positive (B+) nut and wire from the starter motor



Remove the 3 starter motor-to-transaxle bellhousing mounting bolts



Remove the starter motor from the vehicle


The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the underside of the PDC cover for starter relay location.

Hope helped with this (remember rated this help) Good luck.

REMOVAL PROCEDURE

IMPORTANT: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced only as a complete unit.

1. Disconnect the battery ground (negative) cable from the battery.
2. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
3. Remove radiator air baffle assembly.
4. Remove the starter motor BAT terminal nut and electrical leads.
5. Remove the starter motor S terminal nut and electrical lead.
6. Remove the torque converter co
7. Remove the starter motor bolts.
8. Remove the starter motor.

INSTALLATION PROCEDURE

1. Install the starter motor.
2. Install the starter motor bolts. Tighten the starter motor bolts to 47 N.m (35 lb ft)
3. Install the torque converter cover.
4. Install the starter motor S terminal electrical lead and nut. Tighten the starter motor solenoid S terminal nut to 3 N.m (27 lb in).
5. Install the starter motor BAT terminal electrical leads and nut. Tighten the starter motor solenoid BAT terminal nut to 10 N.m (89 lb in) .
6. Install radiator air baffle assembly.
7. Lower the vehicle.
8. Install the battery ground (negative) cable to the battery.