Recommended battery tester: bm-210 or battery MATE or equivalent

 

TROUBLESHOOTING

 

	Unusual condition		Probable cause (Check in numerical order)
Battery	Battery is damaged or weak	1.	Faulty battery
		2.	Current leakage higher than specified value
			– Faulty ignition switch
			– Shorted wire harness
		3.	Faulty alternator charging coil
		4.	Faulty regulator/rectifier
		5.	Open circuit or loose connection in the wire harness

 

 

19-2

BATTERY/CHARGING SYSTEM

SYSTEM LOCATION

REGULATOR/RECTIFIER

 

 

BATTERY

 

 

MAIN FUSE (30 A)

 

ALTERNATOR

 

 

SYSTEM DIAGRAM

 

MAIN FUSE (30 A)

 

G

R/W

Y

Y

Y

 

 

		REGULATOR/RECTIFIER
BATTERY

 

ALTERNATOR

 

 

Y: Yellow

 

G: Green

 

R: Red

 

W: White

 

 

19-3

BATTERY/CHARGING SYSTEM

BATTERY

 

REMOVAL/INSTALLATION

 

 

Connect the positive cable first and then the negative cable.

 

Remove the left side cover (page 2-3). Turn the ignition switch OFF.

 

Disconnect the negative (–) cable [1] first and then the positive (+) cable [2].

 

Remove the bolt [3], battery holder plate [4] and battery [5].

 

Install the battery in the reverse order of removal.

 

TORQUE:

 

Battery holder plate bolt:

 

7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

• Install the battery holder plate by aligning its hook with the slit of the battery case.

• For digital clock setting procedure (page 20-7).

 

		[2]
[1]

Align

 

[3]

[4]

 

[5]

 

VOLTAGE INSPECTION

 

Measure the battery voltage using a commercially available digital multimeter.

VOLTAGE (20°C/68°F):

 

Fully charged: 13.0 – 13.2 V Under charged: Below 12.3 V

 

If the battery voltage is below 12.3 V, charge the battery.

 

BATTERY TESTING

 

Refer to the instructions that are appropriate to the battery testing equipment available to you.

 

TOOL:

 

Battery tester BM-210 or BATTERY MATE or equivalent

 

 

CHARGING SYSTEM INSPECTION

 

CURRENT LEAKAGE INSPECTION

 

Remove the left side cover (page 2-3).
		[1]
With the ignition switch turned OFF, disconnect the
negative (–) cable [1].
Connect the ammeter (+) probe to the wire harness
negative (–) cable and ammeter (–) probe to the battery
negative (–) terminal [2].
			–
+
With the ignition switch turned OFF, check for current
leakage.

• When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range

selected may blow the fuse in the tester.
[2]
• While measuring current, do not turn the ignition
switch ON and engine stop switch to " ". A sudden
surge of current may blow the fuse in the tester.

SPECIFIED CURRENT LEAKAGE: 0.34 mA max.

 

 

19-4

BATTERY/CHARGING SYSTEM

If current leakage exceeds the specified value, a
shorted circuit is likely.
Locate the short by disconnecting connections one by
one and measuring the current.
CHARGING VOLTAGE INSPECTION
Remove the left side cover (page 2-3).
Be sure the battery is in good condition before
performing this test.
Warm up the engine to normal operating temperature.	+
Connect the multimeter between the battery positive (+)
terminal [1] and negative (–) terminal [2].	–

• To prevent a short, make absolutely certain which are the positive (+) and negative (–) terminal or cable.

 

• Do not disconnect the battery or any cable in the charging system without first turning the ignition

 

switch OFF. Failure to follow this precaution can	[2]		[1]
damage the tester or electrical components.

 

With the headlight high beam, measure the voltage on

 

the multimeter when the engine runs at 5,000 min^-1 (rpm).

 

STANDARD:

 

Measured BV < Measured CV < 15.5 V

• BV = Battery Voltage

• CV = Charging Voltage

 

ALTERNATOR CHARGING COIL

 

INSPECTION

 

Remove the left side cover (page 2-3). Disconnect the alternator 3P connector [1].

Measure the resistance between the Yellow wire terminals of the alternator side connector.

 

STANDARD: 0.1 – 1.0 Ω (20°C/68°F)

 

Check for continuity between each wire terminal of the alternator/stator side connector and ground.

 

There should be no continuity.

 

Replace the alternator stator if the resistance is out of specification, or if any wire has continuity to ground.

 

For stator replacement (page 13-4).
[1]

 

19-5

BATTERY/CHARGING SYSTEM

REGULATOR/RECTIFIER

 

REMOVAL/INSTALLATION

 

Remove the radiator reserve tank (page 9-12).
[2]
Disconnect the regulator/rectifier 5P connector [1].		[3]

Remove the bolts [2] and regulator/rectifier [3] from the reserve tank stay.

 

Install the regulator/rectifier in the reverse order of removal.

 

 

[1]

 

SYSTEM INSPECTION

 

Remove the right fuel tank shroud (page 2-4).

 

Turn the ignition switch OFF.

Disconnect the regulator/rectifier 5P connector [1], and check it for loose contacts or corroded terminals.

 

 

If the charging voltage reading (page 19-5) is out of the specification, check the following at the wire harness side connector [1]:

 

Item	Terminal	Specification
Battery charging	Red/white (+)	Battery voltage
line	and ground (–)	should register
Charging coil line	Yellow and	0.1 – 1.0 Ω at
	Yellow	(20°C/68°F)
Ground line	Green and	Continuity should
	ground	exist

 

If all components of the charging system are normal and there are no loose connections at the regulator/ rectifier connector, replace the regulator/rectifier unit.

 

[1]

 

 

[1]

 

 

19-6

LIGHTS/METERS/SWITCHES

 

SERVICE INFORMATION···························20-2

 

SYSTEM LOCATION···································20-2

 

HEADLIGHT ················································20-3

 

POSITION LIGHT ········································20-3

 

TURN SIGNAL LIGHT·································20-4

 

BRAKE/TAILLIGHT·····································20-5

 

SPEEDOMETER··········································20-5 VS SENSOR ················································20-8

 

HIGH COOLANT TEMPERATURE INDICATOR ·················································20-9

 

IGNITION SWITCH····································20-10

 

HANDLEBAR SWITCH·····························20-11

 

BRAKE LIGHT SWITCH ···························20-12

 

NEUTRAL SWITCH ··································20-12

 

SIDESTAND SWITCH·······························20-13

 

CLUTCH SWITCH·····································20-14

 

FUEL GAUGE/FUEL LEVEL SENSOR····················································20-14

 

HORN ························································20-15 TURN SIGNAL RELAY ·····························20-15

 

20-1

LIGHTS/METERS/SWITCHES

SERVICE INFORMATION

 

GENERAL

 

• Note the following when replacing the halogen headlight bulb.

– Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail.

– If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure.

• Be sure to install the dust cover after replacing the headlight bulb.

• A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing.

• Check the battery condition before performing any inspection that requires proper battery voltage.

• A continuity test can be made with the switches installed on the motorcycle.

• The following color codes are used throughout this section.

 

Bu = Blue	G = Green	Lb = Light Blue	O = Orange	R = Red	Y = Yellow
Bl = Black	Gr = Gray	Lg = Light Green	P = Pink	W = White

 

SYSTEM LOCATION

 

 

DIMMER SWITCH

 

 

CLUTCH SWITCH

 

HORN SWITCH

 

 

TURN SIGNAL

 

SWITCH

 

TURN SIGNAL

 

RELAY

 

HORN

 

IGNITION SWITCH

 

FRONT BRAKE LIGHT SWITCH

 

SPEEDOMETER

 

ENGINE STOP SWITCH

 

STARTER SWITCH

 

FUEL LEVEL SENSOR

 

NEUTRAL SWITCH

 

SIDESTAND SWITCH

 

VS SENSOR

 

REAR BRAKE LIGHT SWITCH

 

 

20-2

LIGHTS/METERS/SWITCHES

HEADLIGHT

 

BULB REMOVAL/INSTALLATION

 

Remove the headlight cowl (page 2-5).

Remove the dust cover [1].

Unhook the bulb retainer [2] and remove the headlight

[2]

bulb [3].

Avoid touching halogen headlight bulb. Fingerprints can

create hot spots that cause a bulb to break.

Install the bulb while aligning its tabs with the slots of

the headlight unit.

Hook the bulb retainer into the headlight unit groove.

Install the dust cover tightly against the headlight unit.

Install the headlight cowl (page 2-5).

[3]

[1]

HEADLIGHT UNIT REMOVAL/

INSTALLATION

Remove the headlight cowl (page 2-5).

Remove the screws [1] and headlight unit [2] from the

headlight cowl.

Installation is in the reverse order of removal.

TORQUE:

 

Headlight unit mounting screw: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft)

 

[1]

 

[2]

 

POSITION LIGHT

 

BULB REMOVAL/INSTALLATION

 

Remove the headlight cowl (page 2-5).

Pull out the bulb socket [1] from the headlight case.

Remove the bulb [2] from the socket.

 

Installation is in the reverse order of removal.

 

[2]

 

 

[1]

 

 

20-3

LIGHTS/METERS/SWITCHES

TURN SIGNAL LIGHT

 

BULB REMOVAL/INSTALLATION

 

Remove the screw [1] and turn signal light lens [2] by
releasing its tab [3].	[2]		[3]
While pushing in the bulb [4], turn it counterclockwise to
remove it.
Installation is in the reverse order of removal.
Check that the packing is installed in position and is in
good condition, replace it with a new one if necessary.

 

[4]

 

 

[1]

 

FRONT TURN SIGNAL UNIT

REMOVAL/INSTALLATION

 

Remove the headlight cowl (page 2-5).

 

Disconnect the front turn signal 2P connector [1].

 

– Right side: Light blue

– Left side: Orange

 

Release the wire from the wire band [2]. Left side only: Release the wire from the wire band [3].

 

Remove the nut [4] and front turn signal unit [5]. Installation is in the reverse order of removal.

 

TORQUE:

 

Turn signal unit mounting nut: 21 N·m (2.1 kgf·m, 15 lbf·ft)

Align the flats of the turn signal unit and speedometer stay.