electrical system 5
Contents
1. ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS 5 1 IGNITION SYSTEM cee UM NN UNUM INE 5 3 CHABGING SYSTEM Ga aaa 5 7 STARTER SYSTEM AND SIDE STAND 5 11 IGNITION INTERLOCK SYSTEM SWIT oe ee Nn 5 15 LANP i i aa aaa aa ana nasi JA a 5 16 772 6 65 ee 5 18 FUEL SYSTEM EE EEE 5 21 5 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS dl gt 4 Front brake lamp switch gt Le T co Ar 25 Or LL 6 Starter motor b Rear brake lamp switch ELECTRICAL SYSTEM 5 2 C D I Unit 9 Regulator Rectifier Battery plus terminal 1 Battery minus terminal Be sure not to misassem SAC iti ND ble the position of battery G MEPS plus amp minus terminal ee gt See 2 t L AN 12 Magneto 43 Gear position switch 5 3 ELECTRICAL SYSTEM IGNITION SYSTEM 250 is started as the battery discharged ignition system without a contact point The battery ignition system is composed a rotor with five rotor tip the D C CDI the ignition coil and battery Ignite after permit signal at ignition timing of pick up as electric energy of this battery occur the 1st electric current Therefore a high voltage current is induced in the secondary winding of the ignitio2. Refer to page 3 3 6 With loosen the bolt 2 remove the starter motor Refer to page 3 8 Disassemble the starter motor 9 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear crack or smoothness in the brush holder If the brush has failed replace the brush sub assy E COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut 4 If the commutator is abnomally worn replace the arma ture When surface is discolored polish it with 400 sand paper and clean it with dry cloth ARMATURE COIL INSPECTION Check for continuity between each segment Check for continuity between each segment and the armature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 25002 Segment ELECTRICAL SYSTEM 5 14 STARTER MOTOR REASSEMBLY Reassembly the starter motor Pay attention to the following points Reassembly the starter motor as shown in the illustration 6 Align the mark D on the housing with the line 2 the housing end 5 5 15 ELECTRICAL SYSTEM Apply SUPER GREASE to the O ring D and remount the starter motor AH SUPER GREASE SWITCHES Measure each switch for continuity using a tester If any abnormality is found replace the respectiveswitch assemblies with new ones Pocket tester 09900
3. 25002 IGNITION SWITCH ENGINE STOP SWITCH FRONT REAR BRAKE LAMP SWITCH o 00 ON OO or j ELECTRICAL SYSTEM 5 16 LAMP HEADLAMP TURN SIGNAL LAMP 9 TAIL BRAKE LAMP 5 17 ELECTRICAL SYSTEM 9 COMBINATION METER Remove the combination meter Disassemble the combination meter as shown in the illustration B INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respec tive part Pocket tester 09900 25002 CAUTION When making this test it is not necessary to remove the combination meter 12V 7 X 1 7W T6 5 L LL T ILLUM ILLUM ILLUM TURN R TURN L NELITRAL TACHD METER SI GNAL QoQO OT YB FUEL LENEUTRAL ot Gr ILLUM amp Lg TURN R B TURN L B Y SIGNAL ELECTRICAL SYSTEM 5 18 BATTERY CAUTION OF BATTERY TREATMENT The battery should be well taken care of because it emits flammable gas If you don t follow the instruction in the below there may be a explosion and severe accident Therefore please pay attention to the following points Prohibit positively battery from contacting to short spark or firearms The recharge of battery should be done in the wide place where the wind is well ventilated Please don t recharge it at the sight of wind proof 9 CAUTION OF BAT
4. the battery then lay down at the battery case will be installed the opposite direction positive terminal face on the rightside of the motorcycle as that length of the lead wire has no something extra This time the battery could not lay down per fectly and to occur the short circuit etc if the battery install the opposite direction 5 21 ELECTRICAL SYSTEM ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the main tenance free battery Use the battery at condition of the high temperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric current or voltage when the battery discharged Do not assistance recharge except the right side table times of recharging the battery please do it at the condition of removal of the lead wire A WARNING The firearm is strictly prohibited FUEL SYSTEM 9 FUEL PUMP Q Remove the left frame cover Refer to page 6 3 Q Remove the fuel pump lead wire coupler 9 Refer to page 4 2 Using the pocket tester X 1 Q range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the fuel pump Fuel pump resistance 1 0 10 0 BW BG Pocket tester 09900 25002 9 FUEL PUMP RELAY Q Remove the fuel pump relay coupler B Refer to page 4 2 Using the pocket tester X 1 Q range measure t
5. 09900 25002 SPARK PLUG Clean the plug with a wire brush and pin Use the pin to remove carbon taking care not to damage the porce lain Check the gap with a thickness gauge Spark plug gap 0 7 0 8mm Thickness gauge 09900 20806 5 7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated in figure which is composed of the AC generator regulator rec tifier unit and battery The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current then it charges the battery switch Controlunit d A C generator EHE NR GEM eee ee Regulator Rectifier 9 FUNCTION OF REGULATOR While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage of the regulator the regulator does not function incidentally the generated current charges the battery directly IG switch UU CRT 4 Controlunit A C generator Regulator Rectifier ELECTRICAL SYSTEM 5 8 When the engine rpm become higher the generated voltage of the AC generator also becomes higher and the voltage between points B of the regulator according becomes high and when it reaches the adjusted voltage of the control unit consequently the control unit becomes ON condition On the ON condition of the control unit signal will be sent to the SCR Thyristor gate p
6. TERY ELECTROLYTE TREATMENT Pay attention for the battery electrolyte not to stain the chasis or the humanbogy If be stain the chassis or the humanbody at once wash a vast quantity of water When it be stained clothes should come into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was dropped to the surface of land wash a vast quantity of water Neutralize by hudroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the battery electrolyte filler hole untill use as battery of completely seal type Do not use it except the battery electrolyte Q When pour into the battery electrolyte necessarily use the electrolyte of the specified capacity Do not open the sealing cap after recharge the bat tery eletrolyte 6 Filling electrolyte D The battery is puted on even land remove the alu minum tape sealing 2 Remove the cap at the electrolyte container CAUTION Aluminum tape Do not remove the seal not prick with sharp Filler holes thing EL A 5 19 ELECTRICAL SYSTEM 3 Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it cloes not fall Take precaution not to allow any of the fluid to spill CAUTION There may be a case which can t pour the elec troly
7. and ignition coil The circuit consists of the C D I unit neutral indicator light and switches The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whe ther the side stand is either up or down The gear positoin and side stand switches work together in this system The ignition coil work only in two situations as follows IGNITION ENGINE STOP FUSE SWITCH SWITCH IGNITION COIL NEUTRAL INDICATOR LIGHT BATTERY POSITION SWITCH 2 DOWN POSITION GEAR SIDE STAND SWITCH ELECTRICAL SYSTEM 5 12 TRANSMISSION Neutral Side stand Down OFF IGNITION SWITCH IGNITION COIL NEUTRAL INDICATOR LIGHT SIDE STAND SWITCH DOWN POSITION TRANSMISSION Neutral OFF Side stand Up ON IGNITION SWITCH BATTERY lt i IGNITION COIL NEUTRAL INDICATOR LIGHT GEAR POSITION9 SIDE STAND SWITCH SWITCH OFF UP POSITION mulis 250 is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up Possible Possible Impossible Impossible NOTE 6 On or Up A Off or Down 5 13 ELECTRICAL SYSTEM 9 STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire 1
8. d wires If the tester reads under 72V the AC generator is faulty NO I for Standard NO load perfor 72 99 V at 5 000 rpm mance of AC generator Regulator Rectifier ELECTRICAL SYSTEM 5 10 REGULATOR RECTIFIER Using the pocket tester X 10 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regulator rectifier D Probe of tester Probe of tester 5 11 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components the starter motor starter relay clutch lever position swith C D I unit side stand switch gear position switch starter switch engine stop switch ignition switch and battery Pressing the starter switch on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery CLUTCH LEVER ENGINE STOP IGNITION SWITCH SWITCH SWITCH FUSE CDI E lt START SWITCH DE TANG START RELAY 4 NEUTRAL INDICATOR LIGHT E GEAR POSITION Z Z SWITCH START MOTOR 9 SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stand ignition interlock system prevents the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery
9. he resistance between the lead wires in the following table If the resistance checked is incorrect replace the fuel pump relay Unit Q D Probe of tester Assistance Recharging Standard 0 7 A X5 10 hours X 30 minutes
10. n coil resulting in strong spark between the spark plug gap Magneto C D I Unit SPARK PLUG PLUG CAP FRONT IGNITION COIL IGNITION SWITCH MAGNETO ASS Y m Els CDI B REG BATTERY M REAR IGNITION COIL Dy SIDE STAND SWITHC NEUTRAL SWITCH T7 Ignition coil amp Spark plug ELECTRICAL SYSTEM 5 4 9 INSPECTION E MAGNETO Using the pocket tester measure the resistance between the lead wires in the following table Pick up coil G L Approx 90 110 0 Charging coil Y Y Approx 0 6 0 9 Q Pocket Tester 09900 25002 CAUTION When mounting the stator on the magneto cover apply a small quantily of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 WIRE COLOR L Blue G Green Br Brown B Y Black with Yellow tracer Orange with Black tracer G W Green with White tracer B W Black with White tracer W L White with Blue tracer B CDI UNIT Using the pocket R X 1kQ range measure the resis tance between the lead wires in the following table Unit kQ D Probe of tester o lt ru le 2 Oo um ah Pocket Tester 09900 25002 5 5 ELECTRICAL SYSTEM CAUTION Pay caution as the numerical value differs a little according to the tester Please remind that there be defect which not be identified even though the measurement by using the tester indicates a low
11. robe and SCR will become ON condition Then the SCR becomes conductive to the direction from point to point B Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again At the end of this state since the AC current generated from the AC generator flows into the point reverse current tends to flow to SCR then the circuit of SCR turns to OFF mode and begins to charge the battery again Thus these repetitions maintain charging constant voltage to the battry and protect it from overcharging IG switch D ap m or ontrolunit WE Regulator Rectifier C generator see 5 9 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the DC voltage between the battery terminal and If the tester reads under 13 5 V or over 16 0 V check the AC generator no load performance and regulator rectifier CAUTION When making this test be sure that the battery is full charged condition 13 5 16 0 V at 5 000 rpm Pocket tester 09900 25002 Standard charge NO LOAD PERFORMANCE Disconnect the three lead wires from the ator terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lea
12. te if you put it into electrolyte container slopely 4 Confirmation of pour Make sure that air bubbles are coming up each elec trolyte container and keep this position for about more than 20 minutes CAUTION If no air bubbles are coming up from a filler port tap the button of the two or three times Air bubble ELECTRICAL SYSTEM 5 20 b Separation of electrolyte container After confirming that you entered the electrolyte into bat tery completely remove the electrolyte containers from the battery CAUTION Draw the empty receptacle out slowly because there may be a chance which remaining elec trolyte vaporize 6 Insert of the caps Insert the cap into the filler holes pressing it firmly so that the top of the caps do not protrude above the up per surface of the battery stop cover ST dm 9 BATTERY INSTALLATION 250 s battery installation order pay attention to following points D Romove the seat right frame cover and battery support 2 Lay down positive terminal of the battery at leftside of the battery case on the motorcycle 3 Install positive lead wire at the battery terminal 4 Put on the rubber cap at the positive terminal of the battery S 5 Install negative lead wire at the battery terminal ESS UN Frontside 6 Install the battery support and right frame cover t AMAN A ms CAUTION If install first the lead wire at
13. voltage The range of measurement adjust a x 1kQ unit INSPECTION B IGNITION COIL Checking with Electro Tester Remove the ignition coil 1 2 Make sure that the three needle sparking distance of the electro tester is set at 8 mm 0 3 in Q With the electro tester test the ignition coil for spark ing performance Q if no sparking or orange color sparking occures in the above conditions it may be caused by the defective coil Spark performance Over 8 mm 0 3 in Electro tester 09900 28107 WARNING Do not touch the wire clips to prevent an electric shock when testing CAUTION When using the electro tester follow the instruc tion manual A CAUTION The ignition coil is marked the for front and the R for rear If otherwise it may occure severe damage to the engine ELECTRICAL SYSTEM 5 6 B COIL Checking with Pocket Tester pocket tester an ohm meter may be used instead of the electro tester In either case the igni tion coil is to be checked for continuity in both prima ry and are secondary windings Exact ohmic readings are not necessary but if the windings are in sound condition their continuity will be noted with approxi mate ohmic values Ignition coil resistance Primary 0 19 0 24 Q Tester knob indication x 1 range 5 4 6 6 kQ Tester knob indication x 1kQrange Check to attached plug cap Pocket tester
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