Electric Starter Installation Check List
Fourth phase, Installing starter and testing the wiring.
Last updated 11/01/11
This check list contains the steps to install the starter motor, wiring and testing the wiring.
We estimate this step will take approximately 2 hours.
Line No.
Description
Check 1
Insert the gearbox into the engine cradle.
. 2
Install the gearbox bottom mounting stud that you removed in the first phase
along with the washers and nuts. Do not tighten yet.
. 3
Install the new MK3 top gearbox mounting bolt that came with your fastener kit,
along with the washers and nut.
. 4
Torque the bottom stud nuts and the top nut to 55 ft.lb.
. 5
Clean the oil junction block in preparation to installing.
. 6
Apply a gasket cement to the oil junction block gasket mounted to the crank case in the third phase.
Apply a gasket cement to the oil junction block and install the oil junction block.
. 7
If this is a late model 750 where the breather housing mounts to the lower crank,
clean the breather housing and assemble with a new separator (06-2615) and O-Ring (06-0448), if required.
. 8
If this is a late model 750 where the breather housing mounts to the lower crank,
Place the 1/4" mounting bolts through the tab washers (06-3418) and into the breather housing, then bend the thin tab 90 deg.
against the housing. Slightly bend the wide tab up so as to make it easier to bend when installed.
. 9
If this is a late model 750 where the breather housing mounts to the lower crank,
Apply gasket cement to gasket mounted in the third phase.
Apply gasket cement to the breather housing and install the housing.
. 10
Install the counter shaft sprocket on the gearbox main shaft.
. 11
Place the starter motor with the red and white/red wires attached (should be pre-installed by Old Britts)
over the gearbox main shaft. Make sure the motor is positioned properly and the two wires are threaded through the engine cradle
as shown in the installation manual.
. 12
Put a dab of anti-size on the two short 1" bolts that screw into the starter motor (the top two bolt holes)
and start them into the motor. Do not tighten them, just get them started.
. 13
Start the two long 2 1/4" bolts that pass through the bracket and the engine cradle.
Do not force these bolts, but screw them into the cradle if they have resistance.
. 14
Place one 3/8" washer over the front long bolt that sticks through the engine cradle.
. 15
Place a dab of anti-size inside one of the 3/8 X 24 lock nuts and start it on to the front long bolt.
. 16
Place the 3/8" lug on the black cable over the rear bolt that sticks through the engine cradle.
. 17
Place one 3/8" washer over the rear long bolt.
. 18
Place a dab of anti-size inside one of the 3/8 X 24 lock nuts and start it on to the rear long bolt.
. 19
Torque the top two short bolts to 20 ft.lb.
. 20
Torque the bottom two long bolts to 20 ft.lb.
. 21
Place the modified battery box into the bike.
. 22
Insert the two rear "Z" bracket bolts through the "Z" bracket, spacer, frame and battery box, then tighten.
. 23
Install the modified rear air box plate on to the battery box using the two 1/4" bolts, washers and loc nuts.
. 24
Place the new battery on the rubber battery tray into the battery box and secure with the battery strap.
. 25
Remove the main bikes fuse from the fuse holder.
. 26
For a positive grounded system:
Connect the red starter cable and the bikes power wires (normally the brown/blue wire with the fuse holder)
to the negative battery terminal.
Connect the black starter cable and the bikes ground wires (normally the red wires) to the positive battery terminal.. 27
For a Negative grounded system:
Connect the red starter cable and the bikes power wires to the positive battery terminal.
Connect the black starter cable and the bikes ground wires to the negative battery terminal.. 28
Thread the white/red wire from the starter to the starter button wire. See the instruction manual
for where to find the starter button wire.
. 29
Install the ignition switch into its holder.
. 30
Place a fuse into the fuse holder, turn on the ignition switch and press the starter button
to verify everything is installed correctly.
The starter gear should move out from the motor and rotate clockwise when the starter button is pressed.
.
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& Associates if you have any questions or comments please
contact us at infon@fheaton.com