Kawasaki STX-15F Electric Starter System, Starter Relay Removal, Starter Relay Installation

14-26 ELECTRICAL SYSTEM

Electric Starter System

Starter Relay Removal

•Remove:

Seat (see Hull/Engine Hood chapter)

Rear Storage Pocket (see Hull/Engine Hood chapter) Battery (see this chapter)

•Disconnect the negative battery cable from the battery terminal. (see Battery Removal).

•Disconnect the starter relay lead connector [A].

•Slide out the rubber caps [A].

•Remove the nuts [B] from the battery and starter terminals on the start relay switch.

•Remove the starter relay case bolts [C] and slide the starter relay switch from the relay case [D], being care- ful not to lose any of the insulating washers or grommets.

Starter Relay Installation

•Mount the starter relay switch [A] in the relay case [B]. ○Coat the insulating washers [C] and grommets [D] with

water resistant grease.

○Be certain all insulating washers and grommets are in po- sition.

○Tighten the relay mounting nuts [E] securely.

Torque - Starter Relay Mounting Nuts: 4 N·m (0.40 kgf·m,

35in·lb)

•Replace the gasket [A] with a new one.

•Be sure the dowel pins [B] are in position.

•Be sure the grommet [C] is installed on the relay case [D].

•Be sure the battery cable is connected to the battery ter- minal having red mark.

Torque - Starter Relay Case Bolts: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Starter Cable Mounting Nuts: 4 N·m (0.40 kgf·m,

35in·lb)

Starter Relay Inspection

•Remove the starter relay (see Starter Relay Removal).

•Set hand tester to R × 1 Ω range.

•Connect meter leads to starter relay as shown.

If resistance is less than infinite, the starter relay switch is not returning and must be replaced.

Special Tool - Hand Tester: 57001-1394