Monthly Archives: Март 2014

BATTERY/CHARGING SYSTEM

COMPONENT LOCATION

’05 — ’07 shown:

BATTERY/CHARGING SYSTEM

ALTERNATOR

REGULATOR/RECTIFIER

BATTERY

FUSE 15 A

G : Green R : Red W : White Y : Yellow

SYSTEM DIAGRAM

BATTERY/CHARGING SYSTEM

SERVICE INFORMATION

GENERAL

A WARNING

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.

• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

— If electrolyte gets on your skin, flush with water.

— If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.

• Electrolyte is poisonous.

— If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.

• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.

• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.

• The battery sealing caps should not be removed. Attempting to remove the sealing caps from the cells may damage the battery.

• The maintenance free battery must be replaced when it reaches the end of its service life.

• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same con­ditions contribute to shortening the life span of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years.

• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventu­ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly.

• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load.

• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent sulfation from occurring.

• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery life is lengthened when it is initially charged.

• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).

• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery.

BATTERY TESTING

Refer to the instructions in the Operation Manual for the recommended battery tester. The recommended battery tester

puts a "load" on the battery so the actual battery condition of the load can be measured.

Recommended Battery Tester: Micro 404XL (U. S.A. only), BM-210 or equivalent

SPECIFICATIONS

ITEM

SPECIFICATIONS

Battery

Capacity

12 V-6 Ah

Current leakage

0.1 mA max.

Voltage

(20°C/68°F)

Fully charged

13.0-13.2 V

Needs

charging

Below 12.4 V

Charging cur­rent

Normal

0.6 A/5-10 h

Quick

3.0 A/I. Oh

Alternator

Capacity

78 W/5,000 rpm

TOOLS

Christie battery charger MC1012/2T (U. S.A. only)

BATTERY/CHARGING SYSTEM

Motorcycle battery analyzer Micro 404XL (U. S.A. only)

TROUBLESHOOTING

BATTERY IS DAMAGED OR WEAK

1. BATTERY TEST

Remove The battery (page 17-6).

Check the battery condition using the recommended battery tester.

RECOMMENDED BATTERY TESTER:

Micro 404XL (U. S.A. only), BM-210 or equivalent

Is the battery in good condition7

NO — Faulty battery.

YES — GO TO STEP 2.

2. CURRENT LEAKAGE TEST

Install the battery (page 17-6).

Check the battery current leakage test (Leak test; page 17-7).

Is the current leakage below 0.1 mA?

YES — GO TO STEP 4.

NO — GO TO STEP 3.

3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED Disconnect the regulator/rectifier connector and recheck the battery current leakage.

Is the current leakage below 0.1 mA7

YES — Faulty regulator/rectifier.

NO — Shorted wire harness.

4. ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil (page 17-8).

Check for continuity between Yellow terminal and Ground, White terminal and Ground. Is there continuity?

NO — Faulty charging coil.

YES — GO TO STEP 5.

5. CHARGING VOLTAGE INSPECTION

Measure and record the battery voltage using a digital multimeter (page 17-6).

Start the engine.

Measure the charging voltage (page 17-7).

Compare the measurements to the results of the following calculation.

STANDARD:

Measured BV < Measured CV < 15.5 V

• BV = Battery Voltage

• CV = Charging Voltage

Is the measured charging voltage within the standard voltage?

YES — Faulty battery.

NO — GO TO STEP 6.

6. REGULATOR/RECTIFIER SYSTEM INSPECTION

Check the voltage and resistance at the regulator/rectifier connector (page 17-8).

Are the result of checked voltage and resistance correct?

YES — Faulty regulator/rectifier.

NO — • Open circuit in related wire

• Loose or poor contacts of related terminal

• Shorted wire harness

BATTERY

NEGATIVE CABLE

BATTERY HOLDER

BATTERY/CHARGING SYSTEM

REMOVAL/INSTALLATION

Remove the seat (page 3-3).

Remove the battery holder.

Disconnect the negative (-) cable and then the posi­tive (+) cable, and remove the battery.

Connect the positive terminal first and then the negative cable.

Installation is in the reverse order of removal.

After installing the battery, coat the terminals with clean dielectric grease.

VOLTAGE INSPECTION

Measure the battery voltage using a digital multimeter.

VOLTAGE:

Fully charged: 13.0-13.2 V

Under charged: Below 12.4 V

TOOL:

Digital multimeter Commercially available in

U. S.A.

BATTERY TESTING

Remove the battery (page 17-6).

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

TOOL:

Battery tester Micro 404XL (U. S.A. only),

BM-210 or equivalent

BATTERY CHARGING (U. S.A. only)

Remove the battery (page 17-6).

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

TOOL:

Christie battery charger MC1012/2T (U. S.A. only)

BRAKE PEDAL

REMOVAL

PIVOT BOLT

BRAKE PEDAL

Remove the clip, brake pedal pivot bolt, washer and dust seals.

COTTER

BRAKE PEDAL

JOINT PIN

BRAKE PEDAL

Remove the return spring.

Remove and discard the cotter pin. Remove the joint pin and brake pedal.

INSTALLATION

Connect the brake pedal to the push rod. Install the joint pin and a new cotter pin.

Install the dust seals with their lip side facing out to the brake pedal.

WASHER DUST SEALS

PIVOT BOLT,—

BRAKE PEDAL

Apply grease to the sliding surface of the brake pedal and pivot bolt.

Install the washer and pivot bolt.

Tighten the brake pedal pivot bolt to the specified torque.

TORQUE: 36 N m (3.7 kgf-m, 27 lbf-ft)

Install the brake pedal clip securely.

Install the return spring

REAR BRAKE CALIPER

REMOVAL

Drain the rear brake hydraulic system (page 16-6). Remove the brake pads (page 16-10).

Remove the bolts and brake caliper guard.

Loosen the oil bolt.

Remove the rear wheel (page 15-8).

BRAKE CALIPER/BRACKET ASSEMBLY

REAR BRAKE CALIPER

Slide the brake caliper and bracket assembly back­ward and pull it off of the slide rail on the swingarm.

Remove the brake hose oil bolt, sealing washers and brake hose eyelet.

DISASSEMBLY

Remove the bolts and brake disc cover.

REAR BRAKE CALIPER

REAR BRAKE CALIPER

Remove the caliper bracket from the caliper body.

Remove the brake pad spring from the caliper body. Remove the brake pad retainer from the caliper bracket.

Remove the caliper pin boot and bracket pin boot.

If necessary, lightly apply compressed air to the cal­iper fluid inlet to get piston out.

REAR BRAKE CALIPER

Place a shop rag under the caliper to cushion the piston when it is expelled.

Do not bring the air nozzle too close to the inlet or the pistons may be forced out with excessive force that could cause injury.

Use the air in short spurts.

Be careful not to damage the piston sliding surface.

PISTON

REAR BRAKE CALIPER

SEAL

DUST

INSPECTION

Check the caliper cylinder and piston for scoring,
scratches or damage.

Measure the caliper cylinder I. D.

SERVICE LIMIT: 22.712 mm (0.8942 in)

Push the dust seal and piston seal in and lift them out.

Clean the seal grooves, caliper piston and caliper piston sliding surface with clean brake fluid.

Measure the caliper piston O. D. SERVICE LIMIT: 22.573 mm (0.8887 in)

REAR BRAKE CALIPER

ASSEMBLY

Coat new piston seal with clean brake fluid.

DUST SEAL

PISTON SEAL

CALIPER

PISTON

REAR BRAKE CALIPER

Coat new dust seal with silicone grease.

Install the piston seal, dust seal and caliper piston in their proper locations.

Install the piston and dust seals into the grooves in the caliper body.

Coat the caliper piston with clean brake fluid and install it into the caliper cylinder with its open end facing the pad.

BOOTS

PAD SPRING

CALIPER

CALIPER BRACKET

RETAINER

REAR BRAKE CALIPER

Install the brake pad retainer onto the caliper bracket.

Install the pad spring into the caliper body.

Replace the caliper and bracket pin boots if there is wear, deterioration or damage.

Apply silicone grease to the inside of the boots then install them.

Apply silicone grease to the caliper pin bolt sliding area.

When assembling the caliper and bracket, set the boot into the slide pin groove.

Assemble the caliper and bracket.

BOLTS

REAR BRAKE CALIPER

Install the brake disc cover and tighten the bolts securely.

REAR BRAKE CALIPER

DISC COVER

INSTALLATION

REAR BRAKE CALIPER

Install the brake hose eyelets to the caliper body with new sealing washers and oil bolt.

REAR BRAKE CALIPERInstall the brake caliper/bracket assembly onto the swingarm by aligning the bracket tab with the slide rail on the swingarm.

BRAKE CALIPER/BRACKET ASSEMBLY

Install the rear wheel (page 15-13).

Install the brake pad (page 16-10).

SLIDE RAIL

OIL BOLT

CALIPER GUARD

Push the brake hose eyelet to the stopper on the cal­iper, then tighten the oil bolt to the specified torque.

TORQUE: 34 N m (3.5 kgf m, 25 lbf-ft)

Install the caliper guard and tighten the bolts securely.

Fill and bleed the rear brake hydraulic system (page

16-7).

BOLTS

FRONT BRAKE CALIPER

REMOVAL

Drain the front brake hydraulic system (page 16-6). Remove the brake pads (page 16-10).

Remove the brake hose oil bolt, sealing washers and brake hose eyelet.

FRONT BRAKE CALIPER

PAD SPRING

CALIPER

If necessary, lightly apply compressed air to the cal­iper fluid inlet to get the piston out.

Place a shop rag under the caliper to cushion the piston when it is expelled.

Do not bring the air Use the air in short spurts.

nozzle too close to the inlet or the pistons may be forced out with excessive force that could cause injury.


Push the dust seals and piston seals in and lift them out.

Be careful not to damage the piston sliding surface.

PISTON SEALS

DUST SEALS

FRONT BRAKE CALIPER

Clean the seal grooves, caliper pistons and caliper piston sliding surfaces with clean brake fluid.

INSPECTION

FRONT BRAKE CALIPER

Check the caliper cylinder and pistons for scoring, scratches or damage.

Measure the caliper cylinder I. D.

SERVICE LIMIT: 27.060 mm (1.0654 in)

Measure the caliper piston O. D. SERVICE LIMIT: 26.853 mm (1.0572 in)

ASSEMBLY

PISTON SEALS

Coat new piston seals with clean brake fluid.

FRONT BRAKE CALIPER

Coat new dust seals with silicon grease.

Install each piston seal, dust seal and caliper piston in their proper locations.

Install the piston and dust seals into the grooves in the caliper body.

Coat the caliper pistons with clean brake fluid and install them into the caliper cylinder with their open ends facing the pad.

t

jeirt f J DUST SEALS

CALIPER ^

PISTONS

When assembling Assemble the caliper and bracket.

the caliper and
bracket, set the
boot into the slide
pin groove.

INSTALLATION

Install the caliper/bracket assembly to the fork leg.

Clean and apply locking agent to the caliper mount — h
ing bolt threads.

Install and tighten the mounting bolts to the speci-
fied torque.

TORQUE: 30 N m (3.1 kgf m, 22 Ibf ft)

Install the brake pad retainer onto the caliper
bracket.

Л/оге the installation Install the pad spring into the caliper body. CALIPER

direction of the pad pep|ace the caliper and bracket pin boots if there is BRACKET

sPnn9- wear( deterioration or damage.

Apply silicone grease to the inside of the boots then
install them.

Apply silicone grease to the caliper pin bolt sliding
area.

Install the brake hose eyelet to the caliper body with new sealing washers and oil bolt.

Push the brake hose eyelet to the stopper on the cal­iper, then tighten the oil bolt to the specified torque.

TORQUE: 34 N m (3.5 kgf m, 25 Ibf-ft)

Install the brake pads (page 16-10).

Fill and bleed the front brake hydraulic system (page 16-7).

RETAINER

PAD SPRING

CALIPER

FRONT BRAKE CALIPER

BRAKE HOSE

FRONT BRAKE CALIPER

I CALIPER/BRACKET ASSEMBLY % — v

BOLT

FRONT BRAKE CALIPER

S3» SEALING WASHERS

% И V4

FRONT BRAKE CALIPER

CALIPER GUARD

BOLTS