4 . Examine the carbon brushes for damage to the contact surfaces and measure their length. Replace the brushes as a set if either one measures less than 5.5 mm (0.22 in.), or if they are damaged in any way.
   5 . Brush spring tension should be measured with a small pullscale. Replace the spr ngs if they have weakened to less than 0.4 kg (0.8 lb) tension.
   6. The mica undercut of the commutator should be maintained at 0.3 nun (0.012 in.). Any carbon deposits should be cleaned out of the commutator grooves, and a piece of hacksaw blade or the like used to increase the undercut depth if necessary. Refer to the illustration.
   7. Polish the commutator with fine emery cloth and then clean it thoroughly before installing.
Starter Solenoid
   1. If the battery is in reasonably good condition, and nothing at all happens when the starter button is pushed, check the solenoid.
   2. Disconnect the starter cable at the starter motor. When the button is pushed, there should be an audible "click" which indicates that the solenoid is opening.
   3. If further testing is necessary, remove the solenoid from the machine.
   CAUTION: Be sure to disconnect the cables at the battery before disconnecting the solenoid terminals.
   Connect a fully charged 12volt battery across the solenoid low tension leads and check for continuity across the hightension terminals with an ohmmeter or selfcontained test light. if there is no continuity, replace or repair the solenoid.
   4. Check for continuity across the low tension terminals with an ohmmeter or self powered test light. If there is none, the primary winding of the solenoid is broken, and the unit must be replaced.
   5. The primary cause of solenoid malfunction is pitting and/or burning of the contact points inside. It may be possible to restore a solenoid to serviceable condition by taking it apart and dressing the points with.a file or emery paper. If this doesn't work, replace it.

   6. If starter trouble began just after the starter button housing was disassembled or moved for any reason, check the connections at the switch as they may have come adrift

ELECTRICAL SWITCHES
Most electrical switches can be easily checked with an ohmmeter or a selfpowered low voltage test light. In most cases, the switch is nothing more than a mechanically activated "gate" which must pass or not pass current as needed. Therefore, continuity, or the lack of it, at the right time is what you will be checking for.

Oil Pressure Switch
   1. The oil pressure warning light should come on when the ignition is switched on, and go off as soon as the engine starts.
   2. If the light does not come on, check the bulb first.
   3. If the bulb is good, disconnect the blue/red lead from the switch. Check for continuity between the switch and the engine. There should be continuity when the engine is off, and no continuity when the engine is running.
   4. Ground the blue/red lead coming from the wiring harness to the engine with a short length of jumper wire. With the ignition on and the engine off, the warning light should go on. If it does not, the wire is broken somewhere between the bulb and the switch.

Neutral Switch
   1. The neutral indicator light should go on when the ignition is switched on, and go out when a gear is engaged.
   2. If the indicator light will not go on, check the bulb first.
   3. Disconnect the light green/red lead from the neutral switch on the engine. Check the continuity between the switch itself and the engine. There should be continuity when the transmission is in neutral, no continuity when a gear is engaged. If the switch does not behave in this manner, replace it.
Horn
   1. If the horn will not function, disconnect the

 two leads and connect a 12volt battery directly to the horn terminals. The light green wire is the positive side. If the horn does not sound, it is defective.
   2. If the horn does sound, disconnect the light green lead and connect a voltmeter or simple test light (12volt bulb) between the lead and a good ground. You should get battery voltage when the horn button is pushed. If not, thehorn button may be defective..
   3. Check that there is continuity between the horn's black lead and ground on the frame. If not, the lead is broken.

Ignition Switch
   1. With the key turned to the first position, check for continuity between the black and red leads. If continuity does not exist, replace the switch.
   2. With the key in the first position, continuity must exist between the brown and the brown/white leads.
   3. With the key in the second or "Park" position, continuity must exist between the red and brown leads.
   4. When the ignition switch is in the "Off" position, there must be continuity between the black/white and green leads.
   5. In the "Park" position, there must be continuity between the black/white and green leads.

Brake Light Switches
if neither hand lever or brake pedal will activate the brake light, suspect the bulb.
To check the individual switches, procede as follows:
   1. Check for continuity across the front brake light switch terminals. Continuity should occur when the brake lever has moved about I in. (25 mm), measured at the tip of the lever.
   2. Check for continuity between the black and green/yellow leads to check the rear brake light switch. Continuity should occur when the brake pedal has moved about 25 mm (1 in.). This switch is adjustable.