Battery Terminal Voltage Standard: 12.8 V or more

Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C]

Refresh charge is required [D]

Refreshing Charge

• Remove the battery [A] (see Battery Removal).

• Do refresh charge by following method according to the

WARNING

This battery is sealed type. Never remove sealing cap [B] even at charging. Never add water. Charge with current and time as stated below.

battery terminal voltage.

 

 

 

Terminal Voltage: 11.5 ~ less than 12.8 V

CAUTION

If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on.

Standard Charge 1.2 A × 5 ~ 10 h (see following chart) Quick Charge 5 A × 1 h

Terminal Voltage: less than 11.5 V Charging Method 1.2 A × 20 h

NOTE

○Increase the charging voltage to a maximum voltage of

25 V if the battery will not accept current initially. Charge

for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 min- utes, replace the battery.

Battery [A]

Battery Charger [B] Standard Value [C] Current starts to flow [D]

• Determine the battery condition after refresh charge.

○Determine the condition of the battery left for 30 minutes

after completion of the charge by measuring the terminal

voltage according to the table below.

 

Criteria	Judgement
12.8 V or higher	Good
12.0 ~ lower than 12.8 V	Charge insufficient → Recharge
lower than 12.0 V	Unserviceable → Replace

 

Alternator Cover Removal

• Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

Alternator Lead Connector [A]

 

 

• Place a suitable container under the alternator cover [A], and remove the cover bolts [B].

• Pull the alternator cover outside.

 

Alternator Cover Installation

• Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear

sides of the cover mount.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Check that dowel pins [B] are in place on the crankcase.

• Install a new gasket and the alternator cover.

• Tighten:

Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Stator Coil Removal

• Remove:

Alternator Cover (see Alternator Cover Removal)

Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C]

• Remove the stator coil [D] from the alternator cover.

 

Stator Coil Installation

• Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them.

Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

• Secure the alternator lead with a holding plate, and tighten the bolt.

○Apply a non-permanent locking agent to the threads of

the holding plate bolt.

Torque - Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Apply silicone sealant to the circumference of the alter-

nator lead grommet, and fit the grommet into the notch of

the cover securely.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install the alternator cover (see Alternator Cover Installa- tion).

Alternator Rotor Removal

• Remove the alternator cover (see Alternator Cover Re- moval).

• Remove the starter idle gear, torque limiter and shafts.

• Wipe oil off the outer circumference of the rotor.

• Hold the alternator rotor steady with the rotor holder [A],

and remove the rotor bolt [B] and washer.

Special Tools - Grip: 57001-1591

Rotor Holder: 57001-1658

• Using the flywheel puller [A], remove the alternator rotor from the crankshaft.

Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×

CAUTION

Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.

1.5: 57001-1405

Alternator Rotor Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth.

Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B]

• Apply a thin coat of molybdenum disulfide grease to the

crankshaft [C].

 

 

• Install the starter gear [A] and washer [B].

• Again, clean the crankshaft tapered portion [C] and dry

there.

 

 

• Install the alternator rotor [A] while turning [B] it counter- clockwise.

 

• Install the washer [A].

NOTE

○Confirm the alternator rotor fit or not to the crankshaft

before tightening it with specified torque.

• Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt.

• Install the rotor bolt [B] and tighten it with 70 N·m (7.0

kgf·m, 52 ft·lb) of torque.

• Remove the rotor bolt and washer.

• Check the tightening torque with flywheel puller.

If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15

ft·lb) of drawing torque, it is installed correctly.

If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque.

• Tighten the alternator rotor bolt while holding the alterna-

tor rotor steady with the rotor holder.