service manual 16-17
Contents
1. HP080301W3 C 1 Ignition Switch 3 Regulator Rectifier 5 Main Fuse 30 A 2 Alternator 4 Battery 6 Load 16 32 ELECTRICAL SYSTEM Ignition System A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running This is to prevent igniter damage Do not install the battery backwards The negative side is grounded This is to prevent damage to the diodes and igniter Use the standard regulator rectifier or the igniter will be damaged Spark Plug Removal Front Side e Remove Spark Plug Cap A Spark Plug B Rear Side e Remove Rear Fender see Frame chapter Air Cleaner Cover see Frame chapter Inner Side Cover see Frame chapter Clamp Screws A and Clamps Converter Exhaust Joint Duct B ELECTRICAL SYSTEM 16 33 Ignition System e Remove Spark Plug Cap A Spark Plug B Spark Plug Installation e Tighten Torque Spark Plugs 13 N m 1 3 kgf m 113 in Ib e Fit the spark plug caps securely e Pull up the spark pug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning Inspection e Refer to the Spark Plug Inspection the Periodic Main ten2. 16 14 ELECTRICAL SYSTEM Precautions There are a number of important precautions that should be taken when servicing electrical systems Learn and ob serve all the rules below not reverse the battery lead connections This will burn out the diodes in the electrical parts O Always check battery condition before condemning other parts of an electrical system A fully charged battery is required for conducting accurate electrical system tests O The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them O To prevent damaging electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running O Because of the high current never keep the starter button depressed when the starter motor will not turn over or the current may burn out the starter motor windings Only use an illumination bulb rated for the voltage or wattage specified in the wiring diagram or the handle cover could be warped by excessive heat radiated from the bulb O Take care not to short the leads that are directly con nected to the battery positive terminal to chassis ground O Troubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too m
3. 16 34 Ignition Coil Inspection 16 34 Ignition Coil Primary Peak Voltage ID BOBO 16 36 Crankshaft Sensor Removal 16 36 Crankshaft Sensor Installation 16 37 Crankshaft Sensor Inspection 16 37 Crankshaft Sensor Peak Voltage 17577 72151 16 38 Alternator Rotor Inspection 16 38 Ignition Timing Test 16 39 Vehicle down Sensor Outline 16 39 Vehicle down Sensor Removal 16 40 Vehicle down Sensor Installation 16 40 Vehicle down Sensor Inspection 16 41 Electric Starter System 16 45 Starter Motor Remowval 16 45 Starter Motor Installation 16 45 Starter Motor Disassembly 16 46 Starter Motor Assembly 16 47 Commutator Cleaning Inspection 16 48 Armature Inspection 16 49 Starter Motor Brush Length 16 50 Brush Assembly Inspection 16 50 Brush Plate and Terminal Bolt Spett nonsi naro soo 16 50 Starter Relay Inspection 16 50 Starter Circuit Relay Inspection 16 51 Starter Motor Clutch Remowval 16 52 Starter Motor Clutch Installation 16 53 Starter Motor Clutch Inspection 16 53 Torque Limiter Inspection 16 54 Lighting 16 55 Headlight Beam Vertical Ad Ustmerll eee esee nennt 16 55 Headlight Bulb
4. Lt 7 Alternator Stator Bots 13 13 8 Crankshaft Sensor Mounting Bolts 59 060 s2inb 1 8 13 ped EH Alternator Cover Plugs 18 48 d Alternator Rotor Bolt 127 Alternator Bolt Cover Bolts 8 8 0 90 Alternator Cover Bolts 88 O90 G Apply grease for oil seal and O ring L Apply a non permanent locking agent M Apply molybdenum disulfide grease O Apply engine oil R Replacement Parts 78 in lb 78 in lb 16 6 ELECTRICAL SYSTEM Exploded View SC e 7 lt WO JA SIN QS X TANS gt LA is rS Q 5 y z ELECTRICAL SYSTEM 16 7 Exploded View 2 Ignition Coil Mounting Botts 55 O55 48inib _4 OllPressueSwth 16 15 n 1 1 1 i 1 ES 1 i i 15 6 Neutral Position Switch 5 15 n 8 Fuel Pump Mounting Bolts 20 020 17inb Regulator Rectifier Botts 88 090 T8inlb 10 Vehicle Down Sensor 61 a Pood Me Apply grease for oil seal and O ring L Apply a non permanent locking agent S Follow the specific tightening sequence SS Apply silicone sealant Kawasaki Bond 56019 120 16 8 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 9 Exploded View Radiator Fan Switch 1 8 2 Coolant Temperature Warning Lig
5. A Plate B Crankshaft Sensor C 10025851 0 ELECTRICAL SYSTEM 16 37 Ignition System Crankshaft Sensor Installation e Install Stator Coil Leads A Plate B Crankshaft Sensor C e Tighten Torque Crankshaft Sensor Mounting Bolts 5 9 N m 0 6 kgf m 52 in Ib e Fit the lead grommets into the notch on the alternator COVer Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads Crankshaft Sensor Inspection e Remove the rear fender see Frame chapter e Disconnect the crankshaft sensor lead connector A e Measure the crankshaft sensor resistance O Connect a hand tester between the BK W lead and the BL lead O Set the tester to the x 10 2 range Crankshaft Sensor Resistance 110 140 2 x If the tester does not read as specified replace the crank shaft sensor HPLOBQUG 16 38 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE O Be sure the battery is fully charged e Remove the spark plug caps but do not remove the spark plugs e Disconnect Crankshaft Sensor Wire Connector A Set the hand tester B to the 10 V DC range e Connect the peak voltage adapter C to the hand tester and crankshaft sensor leads in the connector Special Tool Hand Tester 57001 1394 Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI Connections Crankshaft Sensor Wire Adapter Hand Tes
6. Falling temperature Coolant temperature warning light switch resistance Rising temperature Falling temperature ELECTRICAL SYSTEM 16 11 em Standard From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 2 OFF More than 1 MQ From OFF to ON at 112 118 C 234 244 F From ON to OFF at 108 111 C 226 232 F ON less than 0 5 Q OFF More than 1 MQ 16 12 ELECTRICAL SYSTEM Special Tools Hook Wrench Hand Tester 57001 1101 57001 1394 Timing Light Flywheel Puller Assembly 57001 1241 57001 1405 Compression Gauge Gasket Needle Adapter Set 57001 1314 57001 1457 e 5757145757 Parts Location Light Dimmer Switch A Engine Stop Switch B Starter Button C Reverse Power Assist Switch Override D Rear Brake Light Switch E Ignition Switch F Indicator Unit G Front Brake Light Switch H Battery A Fuel Pump Fuel Reserve Switch B in fuel tank Main Fuse 30 A C Starter Relay D Vehicle Down Sensor E Igniter F Ignition Coil Rear G Rear Brake Light Switch H Water Temperature Switch A Radiator Fan Switch B Ignition Coil Front C Spark Plug D Starter Motor E Oil Pressure Warning Light Switch F Crankshaft Sensor G Alternator H Reverse Position Switch A Neutral Position Switch B Regulator Rectifier C Starter Circuit Relays D Radiator Fan Fuse E ELECTRICAL SYSTEM 16 13
7. KAWASAKI Hand Tester Inspect 2 Crankshaft sensor peak 1 Adapter connection is voltage incorrect or adapter is defective 2 Ignition switch and engine stop switch 3 Crankshaft sensor peak voltage Good Replace bad parts Igniter is defective Rep lace igniter Replace bad parts or inspect them with KAWASAKI Hand Tester 16 44 ELECTRICAL SYSTEM Ignition System Ignition System Circuit Y G Y G BR R BR BK Y BK Y BL BL BK W BK W 8 HP10024BW4 C 1 Reverse Switch 5 Ignition Switch 10 Ignition Coils 2 Fuel Pump 6 Reset Connector 11 Spark Plugs 3 Reverse Power Assist 7 Vehicle down Sensor 12 Battery Switch Override 8 Crankshaft Sensor 13 Main Fuse 30A 4 Engine Stop Switch 9 Igniter ELECTRICAL SYSTEM 16 45 Electric Starter System Starter Motor Removal e Remove Converter Intake Duct A Joint Duct B and Collars e Remove Starter Motor Cable A Starter Motor Mounting Bolts B Clamp C Starter Motor D CAUTION Do not tap the end of the starter motor shaft or the motor may be damaged Starter Motor Installation e When installing the starter motor clean the starter mo tor lugs A and crankcase B where the starter motor is grounded the O ring A shows wear or damage or if it is hard ened replace it with a new one Apply a small amount of engine oil to the O ring 16 46 ELECTRICAL SYSTEM Electric Star
8. rider seated Adjust both headlights to the same an gle Headlight Bulb Replacement e Remove Front Fender see Frame chapter Mounting Screws A Headlight Unit B e Remove Headlight Bolts A and Washer Vertical Adjustment Screw B Spring and Nut Headlight Body C e Remove Headlight Connector A Dust Cover B 16 56 ELECTRICAL SYSTEM Lighting System e Push the holder A and turn it counterclockwise e Remove Holder Headlight Bulb B HPL BOO e Insert the new bulb A by aligning the projection B with the notch C in the headlight unit e Push the bulb holder A in turn it clockwise and release it It should lock in position e Fit the dust cover A OFace the TOP mark B upward Lighting System e Install Grommet A Vertical Adjustment Screw Spring and Nut B Damper Collar and Bolt C Taillight Bulb Replacement e Remove Rear Fender see Frame chapter Tail Light Connector A Screws and Collars B Tail Light Assembly C with Cover e Remove Screw A Screw and Collar B Tail Light Cover C e Remove the screws A e Remove the taillight lens B from the taillight assembly ELECTRICAL SYSTEM 16 57 16 58 ELECTRICAL SYSTEM Lighting System e Push the bulb A in turn it counterclockwise and pull it out Be sure the socket is clean e Insert the new bulb by aligning the pins A with the grooves B in the walls of the socke
9. Face the reserve tank breather hose as 3 Reserve Tank Breather Hose shown 4 Cooling Hose 10 Fan Motor Breather Hose 5 Clamp 11 Fan Motor Lead 6 Radiator Hose 17 14 APPENDIX Cable Wire and Hose Routing 1 Radiator Hose 2 Cooling Hose 3 Reserve Tank 4 Radiator Fan Switch 5 Fan Motor Lead 6 Fan Motor Breather Hose 7 Clamp HB090558W4 C 8 Clamp 9 Face the white paint upward 10 To Thermostat 11 To Water Pump 12 To Fan Motor 13 To Final Gear Case APPENDIX 17 15 Cable Wire and Hose Routing D MAAR W Im AN Ae 1 Fuel Tap 2 Fuel Tap Vacuum Hose 3 Clamp 4 Fuel Hose 5 Fuel Filter 6 To Fuel Tank 7 Face the clamp as shown 17 16 APPENDIX Cable Wire and Hose Routing 1 Front Brake Switch Lead 7 Left Handlebar Switch Lead 2 Throttle Cable 8 Parking Brake Cable 3 Front Brake Hose 9 Choke Cable 4 Indicator Unit Lead 10 Shift Control Cable 5 Ignition Switch Lead 11 Shift Control Cable 6 Brake Switch Lead Cable Wire and Hose Routing 1 Throttle Cable 2 Choke Cable 3 Shift Control Cable 4 Clamp the choke cable only with the band 5 Band 6 To Front Side of Shift Control Grip APPENDIX 17 17 HB09058BW4 C 17 18 APPENDIX Cable Wire and Hose Routing Pa oo Sku be cae 1 Final Gear Case Breather Hose 2 Band 3 Rever
10. Replacement 16 55 Taillight Bulb Replacement Radiator Fan System Radiator Fan Circuit Inspection 16 60 Radiator Fan Motor Inspection 16 60 Fuel Pump Fuel Reserve Switch 16 61 Fuel Pump Inspection 16 61 Fuel Reserve Switch Inspection p 16 62 Fuel Reserve Switch Inspection ED bae d OD 16 62 Indiegtor aiu urit 16 64 Indicator Unit Removeal 16 64 Indicator Unit Installation 16 64 Indicator Unit Inspection 16 64 SENTO ecards sao dict 16 67 16 2 ELECTRICAL SYSTEM Brake Light Switch Adjustment Radiator Fan Switch Inspection Coolant Temperature Warning Light Switch Inspection Switch Inspection 30 A Main Fuse Removal Radiator Fan Fuse Removal Main Fuse Inspection Radiator Fan Fuse Inspection Wiring 16 4 ELECTRICAL SYSTEM Exploded View ELECTRICAL SYSTEM 16 5 Exploded View 1 _ Battery Cable Bolts 59 060 52 2 Starter Motor Mounting Bolts 88 090 78inb 3 Starter Motor Terminai Nut 49 oso 4 Starter Motor Terminal Locknut 69 ozo 6tinb Starter Motor Bolts 49 050 6 Starter Motor Clutch Bots 34 35
11. SYSTEM 16 49 6 1 1060851 16 50 ELECTRICAL SYSTEM Electric Starter System Starter Motor Brush Length e Measure the overall length A of each brush Starter Motor Brush Length Standard 12 mm 0 47 in Service Limit 4 mm 0 16 in x If any is worn down to the service limit replace the brush plate assembly Brush Assembly Inspection e Using the x 1 range measure the resistance as shown A Terminal Bolt and Positive Brush B Brush Plate and Negative Brush there is not close to zero ohms the brush lead has open Replace the brush plate assembly Special Tool Hand Tester 57001 1394 Brush Plate and Terminal Bolt Inspection e Using the highest range measure the resistance as fol lows A Terminal Bolt and Right Hand End Cover B Terminal Bolt and Brush Plate x If there is any reading the brush holder assembly has a short Replace the brush plate assembly Special Tool Hand Tester 57001 1394 Starter Relay Inspection e Remove Seat see Frame chapter Starter Relay A Electric Starter System e Connect the hand tester A and a 12 V battery B to the starter relay C as shown the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 range Criteria When battery is connected 0 2 When battery is disconnected gt Q Special Tool Hand Tester 5
12. for 3 minute HP22008BS1 C ELECTRICAL SYSTEM 16 63 Fuel Pump Fuel Reserve Switch Fuel Pump Fuel Reserve Switch Circuit HP22005BW3 C 1 Indicator Unit 2 Fuel Level Sensor 3 Fuel Pump 4 Igniter 5 Reset Connector 6 Main Fuse 30 A 7 Battery 8 Ignition Switch 16 64 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Removal e Remove Air Cleaner Cover see Frame chapter Indicator Unit Lead Connector A Handlebar Cover and Indicator Unit B e Remove Bolts A Handle Holders B Handlebar Assembly e Remove the indicator unit from handlebar cover CAUTION Do not drop the indicator unit Indicator Unit Installation e Install Indicator Unit Lead Connector Handlebar Assembly O Be sure the indicator unit lead A placed under the han dlebar B e Install the removed parts CAUTION Do not drop the indicator unit Indicator Unit Inspection e Remove Indicator Unit see Indicator Unit Removal ELECTRICAL SYSTEM 16 65 Indicator Unit Check1 Indicator Light Inspection e Using the auxiliary leads connect a 12 V battery to the indicator unit connector as follows Fuel Indicator Light A Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 2 If indicator light does not go on replace the indicator unit Check2 LED light Emitting Diode Light Inspection
13. rectifier is defective x If the test light does not turn on continue the test 6 09060351 C 16 30 ELECTRICAL SYSTEM Charging System Regulator Circuit Test 2nd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Apply 12 V to the BR terminal e Check Y1 Y2 and Y3 terminals x If the test light turns on the regulator rectifier is defective x lf the test light does not turn on continue the test Regulator Circuit Test 3rd Step e Connect the test light and a 12 V battery in the same man ner as specified in the Regulator Circuit Test 1st Step e Momentarily apply 24 V to the BR terminal by adding a 12 V battery e Check Y1 Y2 and Y3 terminals CAUTION Do not apply more than 24 V to the regulator recti fier Do not leave the 24 V applied for more than a few seconds or the unit will be damaged the test light did not light when the 24 V was applied momentarily to the BR terminal the regulator rectifier is defective x If the regulator rectifier passes all of the tests described it may still be defective If the charging system still does not work properly after checking all of the components and the battery test the regulator rectifier by replacing it with a known good unit GP090805S1 C ELECTRICAL SYSTEM 16 31 Charging System Charging System Circuit S gt 2
14. x If the reading is below the specified refreshing charge is required Battery Terminal Voltage Standard 12 6 V or more 25 50 75 100 Battery Charge 4 K Terminal Voltage V Refreshing Charge 5 Good is required 8 08010951 C Refreshing Charge e Remove the battery A see Battery Removal e Refresh charge by following method according to the bat tery terminal voltage A WARNING This battery is sealed type Never remove seal sheet B even at charging Never add water Charge with current and time as stated below Terminal Voltage 11 5 less than 12 5 V Standard Charge 1 4A x 5 10 h see following chart Quick Charge 6 0A x 1 0h CAUTION If possible do not quick charge If the quick charge is done due to unavoidable circumstances do the standard charge later on lt m o e 11 6 11 8 12 0 12 2 12 4 12 6 12 8 13 Battery Terminal Voltage V 6208011151 C Terminal Voltage less than 11 5 V Charging Method 1 4 A x 20h 16 22 ELECTRICAL SYSTEM Battery NOTE O 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 D decrease the voltage and charge by the standard charging method described on the battery case I
15. 7001 1394 Starter Circuit Relay Inspection e Remove Seat see Frame chapter Rear Fender see Frame chapter Starter Circuit Relays A Brake and Neutral Switch Cir cuit O The starter circuit relays for the brake and neutral switch circuits are identical e Connect the hand tester A and a 12 V battery B to the starter circuit relay C as shown x lf the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Hand Tester Range x 1 Criteria When battery is connected gt 0 Q When battery is disconnected gt 2 Relay Coil Terminals 1 and 2 Relay Switch Terminals 3 and 4 ELECTRICAL SYSTEM 16 51 GP12070382 16 52 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit gt gt gt lt 2 HP110301W3 1 Engine Stop Switch 6 Starter Circuit Relay 11 Battery 2 Starter Button Brake 12 Starter Circuit Relay 3 Front Brake Light Switch 7 Ignition Switch Neutral 4 Parking Brake Light 8 Starter Motor 13 Neutral Switch Switch 9 Starter Relay 5 Rear Brake Light Switch 10 Main Fuse 30A Starter Motor Clutch Removal e Remove the alternator rotor see Alternator Rotor Re moval e Hold the rotor with the flywheel holder and take out the starter motor clutch bolts A Special Tool Flywheel Holder 57001 1313 ELECTRICAL SYSTEM 16 53 Electric Starter System e Take
16. AL SYSTEM 16 41 Ignition System Vehicle down Sensor Inspection NOTE O Be sure the battery is fully charged Vehicle down Sensor Power Source Voltage e Remove Seat see Frame chapter Vehicle down Sensor Lead Connector e Connect Vehicle down Sensor Lead Connector A harness side Digital Volt Meter B 1 Connections to Connector 12 V circuit Meter Connector BR Lead C Meter Connector BK Y Lead D e Turn the ignition switch ON and measure the power source voltage Vehicle down Sensor Power Source Voltage WP100058 1 C Standard Battery Voltage 12 5 V or more e Turn the ignition switch OFF If there is no battery voltage check the following Main Fuse 30A Ignition Switch Wiring for Vehicle down Sensor Power Source Il Connections to Connector 5 V circuit Meter Connector Y G Lead E Meter Connector BK Y Lead D e Turn the ignition switch ON and measure the power source voltage Vehicle down Sensor Power Source Voltage Standard about 5 V e Turn the ignition switch OFF If there is no standard voltage check the following HRIO0008 1 0 Igniter Wiring for Vehicle down Sensor Power Source 16 42 ELECTRICAL SYSTEM Ignition System Vehicle down Sensor Output Voltage e Remove the vehicle down sensor see Vehicle down Sensor Removal e Connect the vehicle down sensor A to the connector of the harness e Hold the sensor almost vertical B with the arrow mar
17. AL SYSTEM 16 61 Fuel Pump Fuel Reserve Switch Fuel Pump Inspection Fuel Pump Supply Voltage Inspection e Turn the ignition switch OFF e Remove Seat Fuel Pump Lead Connector A Connect a hand tester B with suitable leads as shown Hand Tester Fuel Pump Connector BR Terminal Hand Tester Fuel Pump Connector BK R Termi nal e Turn the ignition switch ON and run the engine with the transmission in neutral e Measure the fuel pump supply voltage Fuel Pump Supply Voltage Standard near the Battery Voltage xf the reading is not as specified replace the igniter x lf the reading is as specified check the fuel pump Fuel Pump Operational Inspection e Remove Fuel Pump see Fuel System chapter Prepare a container filled with kerosene Prepare the rubber hoses and connect them to the pump fitting e Connect a suitable pressure gauge to the outlet hose as shown Fuel Pump A Pressure Gauge B Outlet Hose C Kerosene D Battery E 12V Connect the pump leads to the battery using auxiliary wires as shown Battery Fuel Pump Connector BR Terminal Battery Fuel Pump Connector BK R Terminal x If the pump does not operate the pump is defective Re place the fuel pump the pump operates is normal close the outlet hose while operating the fuel pump e When the pump stops read the pressure gauge x If the pressure gauge reading is out of the specified pres
18. Accessory 10 Battery 4 Fuel Tank Breather Hose 11 Fuse Case For Radiator Fan 5 To Tail Brake Light 12 Spare Fuse 6 Vehicle down Sensor 13 Reset Connectors 7 Starter Relay Main Fuse 17 22 APPENDIX Cable Wire and Hose Routing H809063B83 C 1 To Tail Brake Light 8 Clamp 2 Clamp 9 Clamp 3 Run the main harness under the seat 10 Clamp bracket 11 To Right Headlight 4 Clamp With the Fuel Hose 12 Rear Brake Light Switch 5 Igniter 13 Band With the Final Gear Case Breather 6 Ignition Coil Rear Hose 7 Band Face the end of the band upward APPENDIX 17 23 Cable Wire and Hose Routing A e pax d 7 gt e C H809064BW4 C 1 Clamp 5 Clamp the fuel hose and main harness 2 Clamp 6 Through the hoses above the main har 3 Fuel Tank Breather Hose ness 4 Fuel Hose 7 Clamp 17 24 APPENDIX Cable Wire and Hose Routing 1 Through the brake hose to the clamp Left Side Only 2 Through the brake hose to the clamp on the left side suspension arm 3 Fit the grommet to the frame clamp HB0S0058W3 C
19. ELECTRICAL SYSTEM 16 1 Electrical System TABLE OF CONTENTS EXPOS rorem 16 4 swine 16 10 Special Tools 16 12 Parts Looabligni ues ecce cns 16 13 PiGCgutiS uiii 16 14 Electhpal VIDE 16 16 Wiring Inspection 16 16 16 17 Battery 16 17 Battery Installation 16 17 Electrolyte Filling 16 17 10 16 19 Precaution Sannea 16 19 Bnterchalt Busen eo ba rei irc 16 20 Charging Condition Inspection 16 21 Refreshing Charge 16 21 Charging Sysipm uum ania 16 23 Alternator Cover Remowval 16 23 Alternator Cover Installation 16 24 Alternator Rotor Removal 16 25 Alternator Rotor Installation 16 26 Alternator Stator Removal 16 26 Alternator Stator Installation 16 26 Regulator Rectifier Output Voltage IriSpetion ecce 16 27 Alternator Inspection 16 28 Regulator Rectifier Inspection 16 29 System sucesor ias 16 32 Spark Plug Removal 16 32 Spark Plug Installation 16 33 Spark Plug Cleaning Inspection 16 33 Spark Plug Gap Inspection 16 33 Ignition Coil Removal 16 33 Ignition Coil Installation
20. OOBANS Troubleshooting Guide Cable Wire and Hose Routing APPENDIX 17 1 Appendix TABLE OF CONTENTS 17 2 APPENDIX Troubleshooting Guide NOTE O This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure No fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed
21. RICAL SYSTEM 16 17 Battery Removal Turn off the ignition switch e Remove the seat see Frame chapter Loosen the bolts A of the battery holder B e Remove the battery with the holder and the case e Disconnect the battery negative cable C first and then the positive cable D e Take out the battery E Battery Installation e Turn off the ignition switch Put the battery with the case and the holder in place e Connect the positive cable first and then the negative ca ble Put a light coat of grease on the terminals to prevent cor rosion e Tighten the battery holder bolts Electrolyte Filling e Make sure that the model name A of the electrolyte con tainer matches the model name B of the battery These names must be the same Battery Model Name KMX 14 BS CAUTION Be sure to use the electrolyte container with the same model name as the battery since the elec trolyte volume and specific gravity vary with the battery type This is to prevent overfilling of the electrolyte shorting the battery life and deteriora tion of the battery performance Check to see that there is no peeling tears or holes in the seal sheet on the top of the battery e Place the battery on a level surface e Remove the seal sheet CAUTION Do not remove the aluminum seal sheet A sealing the filler ports B until just before use NOTE OA battery whose seal sheet has any pee
22. Using the auxiliary leads connect a 12 V battery to the indicator unit connector as follows Neutral Indicator Light LED B Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 3 Reverse Indicator Light LED C Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 4 HP20038852 C Water Temperature Warning Light LED D Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 5 Oil Pressure Warning Light LED E Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 6 Belt Indicator Light LED F Battery Positive Terminal to Terminal 1 Battery Positive Negative to Terminal 7 each LED light does not go on replace the indicator unit 16 66 ELECTRICAL SYSTEM Indicator Unit Indicator Unit Circuit gt gt lt HP20035BW4 C 1 Indicator Unit 5 Igniter 8 Ignition Switch 2 Neutral Switch 6 Oil Pressure Switch 9 Main Fuse 30A 3 Reverse Switch 7 Water Temperature 10 Battery 4 Fuel Reserve Switch Switch Switches Brake Light Switch Adjustment e Refer to the Brake Light Switch Inspection in the Periodic Maintenance chapter Radiator Fan Switch Inspection e Remove Radiator Fan Switch see Cooling System chapter Suspend the fan switch A in a container of coolant so that the te
23. adiator Fan Fuse Removal e Remove Seat see Frame chapter Fuse Case Cover A Pull out the fuse from the fuse case Spare Fuse B Main Fuse Inspection e Inspect the fuse element If it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components GP190401S1 C Fuses Radiator Fan Fuse Inspection e Remove the fuse see Radiator Fan Fuse Removal e Inspect the fuse element lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Fuse Element A Blown Element B CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components ELECTRICAL SYSTEM 16 71 6 20000 51 16 72 ELECTRICAL SYSTEM Wiring Diagram Frame Ground Terminal Ignit
24. ance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Inspection the Periodic Main tenance chapter Ignition Coil Removal Front Side e Remove Spark Plug Cap A Primary Lead Connectors B Bolt C Ignition Coil D Rear Side e Remove Rear Fender see Frame chapter Air Cleaner Cover see Frame chapter Inner Side Cover see Frame chapter Converter Exhaust Joint Duct see Spark Plug Removal Rear Side Spark Plug Cap A Primary Lead Connectors B Bolt C Ignition Coil D 16 34 ELECTRICAL SYSTEM Ignition System Ignition Coil Installation e Connect the primary leads to the ignition coil terminals as shown Front Side G W Lead Mark A BK Y Lead Mark Rear Side BL W Lead gt Mark A BK Y Lead Mark Ignition Coil Inspection e Remove the ignition coil e Measure the arcing distance with a coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance Ignition Coil Arcing Distance 7 mm or more WARNING To avoid extremely high voltage shocks do not touch the ignition coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective e To determine which part is defecti
25. coolant Cooling system component incorrect Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan switch trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged Over Cooling Cooling system component incorrect Radiator fan switch trouble Thermostat trouble Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly in stalled too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive pulley spring incorrect installed too tight Driven pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift shaft bent or seized Gear stuck on the shaft Shift control grip damaged Shift control cable maladjusted Reverse lock maladjusted Jumps out of gear Shifter groove worn Gear dogs worn Shift block
26. d and the rotor must be replaced Special Tool Hand Tester 57001 1394 ELECTRICAL SYSTEM 16 29 Charging System Regulator Rectifier Inspection e Remove Connectors A disconnect Bolts B and Regulator Rectifier C Rectifier Circuit Check e Check conductivity of the following pair of terminals Rectifier Circuit Inspection Tester WIR Y1 WIR Y2 WIR Y3 connection BK Y1 BK Y2 BK Y3 The resistance should be low in one direction and more than ten times as much in the other direction If any two Y3 leads are low or high in both directions the rectifier is 9006 5 C defective and must be replaced NOTE O The actual meter reading varies with the meter and the individual rectifier Generally speaking the lower read ing should be from zero to one half of the scale Regulator Circuit Check To test the regulator out of circuit use three 12 V batteries and a test light 12 V 3 6 W bulb in a socket with leads CAUTION The test light works as an indicator and also a cur rent limiter to protect the regulator rectifier from ex cessive current Do not use an ammeter instead of a test light e Check to be sure the rectifier circuit is correct before con tinuing Regulator Circuit Test 1st Step e Connect the test light and the 12 V battery to the regula tor rectifier as shown Check Y1 Y2 and terminal respectively If the test light turns on the regulator
27. der head not sufficiently tightened down No valve clearance Troubleshooting Guide Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Other Carburetor vacuum piston doesn t slide smoothly Engine oil viscosity too high Brake dragging Igniter trouble Final gear case oil viscosity too high Poor Running or No Power at High Speed Firing incorrect Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Pickup coil trouble Igniter trouble Ignition coil trouble Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needle jet clogged Fuel level too high or too low Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose Air cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn wea
28. e Wire and Hose Routing POS pv oF E F AT KH 1 Clamp 2 Engine Ground Lead 3 Install the clamp on the engine ground lead APPENDIX 17 9 Cable Wire and Hose Routing FORWARD HB08019BW4 C 1 Water Pipe 7 Carburetor 2 White Paint 8 Mark 3 Clamps 9 Cooling Hose 4 Cooling Hoses 10 Assemble Angle about 45 4 and 9 5 Coolant Filter Body hoses 6 Coolant Filter 11 Cooling Hose 17 10 APPENDIX Cable Wire and Hose Routing 480905184 C 1 White Paint 8 Tube 2 Water Pipe 9 Breather 3 Clamp 10 Pump Cover 4 Cooling Hose 11 Mark 5 To Carburetor 12 To Radiator 6 Carburetor Overflow Tube 13 Duct 7 Exhaust Pipe Cover 14 Face the clamp screw as shown APPENDIX 17 11 Cable Wire and Hose Routing HB09052BN4 C 1 Air Cleaner Duct 8 Coolant Valve 2 Clamps 9 Coolant Tube 3 Clamps 10 Starter Cable 4 Boots 11 Carburetor 5 Clamp 12 Clamps 6 Vent Hose 13 Air Vent Tube 7T To Crankcase 17 12 APPENDIX Cable Wire and Hose Routing ge A i x x 1 Clamps 7 Drain Plug 2 Bands 8 Drain Hose 3 Ignition Coil Rear 9 Vent Hose 4 Clamp 10 Align the mark 5 Clamp 11 Fit the projection and groove of the each 6 Clamp ducts APPENDIX 17 13 Cable Wire and Hose Routing H8080548W4 C 1 Coolant Temperature Warning Light 7 Radiator Switch 8 Forward 2 Reserve Tank 9
29. e engine speed is low and as the engine speed in creases the readings should also increase Regulator Rectifier Output Voltage Tester Range Reading Tester to Tester to 25 V DC Battery Battery 14 15V e Turn off the ignition switch and disconnect the hand tester x If the regulator rectifier output voltage is between the val ues given in the table the charging system is working nor mally x If the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open XIf the battery voltage does not increase as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective ELECTRICAL SYSTEM 16 27 16 28 ELECTRICAL SYSTEM Charging System Alternator Inspection There are three types of alternator failures short open or loss in rotor magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromag netic field or just by aging will result in low output To check the alternator output voltage perform the follow ing procedures O Remove the rear fender see Frame chapter O Disconnect the alter
30. emoval but do not remove the spark plug e Measure the primary peak voltage as follows O Connect a commercially peak voltage adapter A to the hand tester B 250 V DC range Install the needle adapters C on the peak voltage adapter leads Special Tools Hand Tester 57001 1394 Needle Adapter Set 57001 1457 Recommended Tool Peak Voltage Adapter Type KEK 54 9 B Brand KOWA SEIKI O Insert the needle adapter inside the seal of the G W front or BL W rear lead in the ignition coil D until the needle reaches the terminal in the ignition coil O Install a new spark plug E into the spark plug cap and ground it to the engine A WARNING To avoid extremely high voltage shocks do not touch the spark plugs or tester connections e Turn the ignition switch ON rotate the engine for 4 5 seconds with the transmission in neutral to measure the primary peak voltage e Repeat the measurements 5 times for one ignition coil Ignition Coil Primary Peak Voltage Standard 50 V or more e Repeat the test for the other ignition coil the reading is less than the specified value check the following Ignition Coils see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection x If the ignition coils and crankshaft sensor are normal see the Ignition System Troubleshooting chart Crankshaft Sensor Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor Mounting Bolts
31. ets to lose magnetism 16 26 ELECTRICAL SYSTEM Charging System Alternator Rotor Installation Clean A the inside of the rotor and the end of the crank shaft e Fit the rotor onto the crankshaft so that woodruff key B fits in the groove C in the hub of the rotor e Install the torque limiter A e Install the alternator rotor B while turning the starter clutch gear C Alternator Stator Removal e Remove Alternator Cover see Alternator Cover Removal Crankshaft Sensor A see Crankshaft Sensor Re moval Bolts B and Alternator Stator C Alternator Stator Installation e Tighten Torque Alternator Stator Bolts 13 N m 1 3 kgf m 113 in Ib e Install Crankshaft Sensor see Crankshaft Sensor Installation e Fit the lead grommets into the notch on the alternator cover Grommets A for Alternator Leads Grommets B for Crankshaft Sensor Leads Charging System Regulator Rectifier Output Voltage Inspection e Remove the seat see Frame chapter Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions Check that the ignition switch is turned off and connect a hand tester to the battery terminals Special Tool Hand Tester 57001 1394 e Start the engine and note the voltage readings at various engine speeds with the headlight turned on and then off The readings should show nearly battery voltage when th
32. f the battery will not accept current after 5 min utes replace the battery Battery A Battery Charger B Standard Value C e Determine battery condition after refreshing charge Determine the condition of the battery 30 minutes after completion of the charge by measuring the terminal volt age according to the table below Criteria Judgement Unserviceable gt Replace GP08011351 Charging System Alternator Cover Removal e Drain the coolant see Cooling System chapter e Remove Bolts A and Alternator Bolt Cover B Water Pump Cover C and Impeller see Cooling Sys tem chapter e Remove Torque Converter Cover see Converter System chap ter e Remove the three bolts of the drive pulley cover except for at the dowel pin parts A as shown B Arrow e Install and tighten the drive pulley holder A and the three bolts B Special Tool Drive Pulley Holder 57001 1520 C Arrow e Holding the drive pulley with the drive pulley holder loosen the alternator rotor bolt A e Remove Alternator Rotor Bolt ELECTRICAL SYSTEM 16 23 16 24 ELECTRICAL SYSTEM Charging System e Remove Collar A O Install the M6 bolt B to the collar and remove it e Place an oil pan under the engine left side e Remove Alternator and Crankshaft Sensor Lead Connectors dis connect Alternator Cover Bolts A Alternator Cover B Clamp C Alternator Cover Installa
33. fficient or too thin Final gear case noise Insufficient lubricant Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Rear brake noise Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level too high Black Smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Damage tie rod end APPENDIX 17 5 Handlebar shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem clamp bolt loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air pressure unbalanced Front shock absorber unbalanced Shock ab
34. h across the connector and the body at the temperatures shown in the table If the hand tester does not show the specified values re place the switch Coolant Temperature Warning Light Switch Resistance QhRising temperature From OFF to ON at 112 118 C 234 244 F CFalling temperature From ON to OFF at 108 111 C 226 232 F ON Less than 0 5 2 OFF More than 1 Switch Inspection Using the hand tester check to see that only the con nections shown in the table have continuity about zero ohms O For the handlebar switches ignition switch refer to tables in the Wiring Diagram x lf the switch has an open or short repair or replace it with a new one HP14000BS2 C Switches Neutral Switch Connection When transmission is in neutral When transmission is not in neutral A Neutral Switch Reverse Switch Connections SW Terminal When transmission is in reverse Oo When transmission is not in reverse mp B Reverse Switch Oil Pressure Switch Connections ia I T When engineering Engine lubrication system is in good condition ELECTRICAL SYSTEM 16 69 HPT4B012 16 70 ELECTRICAL SYSTEM Fuses 30 A Main Fuse Removal e Remove Seat see Frame chapter Starter Relay and 30A Main Fuse Connector A e Pull out the main fuse B from the starter relay with a needle nose pliers R
35. has no prob lem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loos ened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medical attention if severe Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electri cal system Therefore replace a sealed battery only on a vehicle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a vehicle which had an ordinary battery as original equipment the sealed battery s life will be shortened ELECTRICAL SYSTEM 16 21 Battery Charging Condition Inspection Battery charging condition can be checked by measuring battery terminal voltage e Remove the battery see Battery Removal CAUTION Be sure to disconnect the negative lead first e Measure the battery terminal voltage NOTE 6 08070351 Measure with a digital voltmeter A which can be read to one decimal place voltage
36. ht Switch 69 oza 61 in Ib 2 SS Apply silicone sealant Kawasaki Bond 56019 120 16 10 ELECTRICAL SYSTEM Specifications NENNEN Standard Charging System Alternator type Charging voltage Regulator rectifier output voltage Alternator output voltage Stator coil resistance Ignition System Spark plug Spark plug gap Spark plug cap resistance Ignition coil 3 needle arcing distance Primary winding resistance Secondary winding resistance Primary peak voltage Crankshaft sensor resistance Crankshaft sensor peak voltage Vehicle down Sensor Detection method Detection angle Detection time Output voltage Electric Starter System Starter motor Commutator diameter Brush length Fuel Pump Fuel pump pressure Switches Brake light switch timing Radiator fan switch resistance Rising temperature Sealed Battery 12 V 12 Ah Three phase AC 14 15 V 36 54 V 3 000 r min rpm 0 33 0 49 Q 0 7 0 8 mm 0 028 0 031 in 3 75 6 25 kQ 7 mm 0 28 in or more 0 09 0 13 2 3 8 5 8 kO 50 V or more 110 140 0 1 8 V or more Magnetic flux detection method More than 65 5 for each bank Within 0 5 1 0 sec in the text 28 mm 1 10 in 12 mm 0 47 in 27 mm 1 06 in 4 mm 0 16 in 17 7 22 6 kPa 0 18 0 23 kgf cm 2 6 3 3 psi ON after 10 mm 0 4 in of pedal travel From OFF to ON at 96 100 C 205 212 F Specifications
37. ion cs Switch Reverse Neutral Switch Switch 2 2 Radiator o BL W Fan Switch A aL Radiator BL 5 BK Y M z Horn s 12V18W Ss 5 Headlight Right MK 12V45 45W Bk Y Indicator Unit Fuel Indicator Light Neutral Indicator Light LED Reverse Indicator Light LED Water Temperature Warning Light LED 011 Pressure Warning Light LED Belt Indicator Light LED Headlight Left M MN 12V45 45M f Water xx aa 1 0 8 IC Temperature Switch e 41 62 CP Left Handlebar Switches 1 Light Dimmer Switch Crankshaft 2 Engine Stop Switch Pressuer Sensor 3 Starter Button Switch 4 Reverse Power Assist Switch Alternator Left Handlebar Switch Connections color BR Color ar Y R cotor vn color Y Bx eer 41 I seq 1 e em O amp OO W2L0008AN5 C ELECTRICAL SYSTEM 16 73 Wiring Diagram Radiator Resorve Fan Fuse Rear Parking front 20 Starter Light Light Switch Switch Switch Light Ciroult Relay Brake Regulator Rectifire Tail Brake Light 12V 21 5 V ASHE 9 4 A ss 8 88 ue ue 1 we Jj Connector EUM HI IRI Vehicle down Sensor Starter Circuit Neutral 12V14Ah v e gt Starter Motor 98052 00084 W2RO
38. k broken or sticking APPENDIX 17 3 Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Igniter trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect Igniter trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Compression release cam K A C R sticks close Engine load faulty Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Final gear case overheating Insufficient oil Bevel gears maladjusted Coolant incorrect Coolant level too low Coolant deteriorated 17 4 APPENDIX Troubleshooting Guide Thick
39. k pointed up e Connect Vehicle down Sensor Lead Connector C Digital Volt Meter D Needle Adapters E Special Tool Needle Adapter Set 57001 1457 Connection to Connector 5 V circuit Meter Connector Y G Lead F Meter Connector BK Y Lead e Turn the ignition switch ON and measure the output volt age with the connector joined Vehicle down Sensor Power Output Voltage Standard 0 4 1 4 V with sensor arrow mark pointed up e Tilt the sensor 60 70 or more H right or left and mea sure the output voltage O The time lag is from 0 5 to 1 second HP100078S2 C Vehicle down Sensor Power Output Voltage Standard 3 7 4 4 with sensor tilted 60 70 more right or left the output voltage is out of the specified replace the vehicle down sensor ELECTRICAL SYSTEM 16 43 Ignition System Ignition System Troubleshooting Faulty ignition No spark No good Battery Inspection Charge or replace battery Good No good i Ignition system wiring and connector inspection pedi eg Good No good Spark plug inspection Replace spark plug No good Plug cap inspection Replace plug cap Good No good Vehicle down sensor inspection Replace vehicle down sensor Good No good i Ignition coil primary peak voltage inspection kien then the Good Ignition coil is defective Voltage is zero or Inspect Replace ignition coil almost zero 1 Lower resistance in a hand tester Use
40. l the plate A on the left end cover B P e Align the mark A on the left end cover with the mark B on the yoke e Tighten Torque Starter Motor Bolts 4 9 N m 0 50 kgf m 43 in Ib 1 012 Commutator Cleaning Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves 6 11061051 Electric Starter System Measure the diameter A of the commutator B Replace the starter motor with a new one if the commu tator diameter is less than the service limit Commutator Diameter Standard 28 mm 1 10 in Service Limit 27 mm 1 06 in Armature Inspection e Using the 1 range measure the resistance between any two commutator segments A there is a high resistance or no reading between any two segments a winding is open Replace the starter motor Using the highest range measure the resistance between the segments and the shaft B e f there is any reading at all the armature has a short Replace the starter motor Special Tool Hand Tester 57001 1394 NOTE O Even if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one ELECTRICAL
41. ling tears holes or from which the air sucking sound was not heard requires a refreshing charge initial charge 6208040751 C gp070004 tif 16 18 ELECTRICAL SYSTEM Battery e Take the electrolyte container out of the vinyl bag e Detach the seal caps A from the container NOTE O Do not discard the seal caps because it is used as the battery plugs later O Do not peel back or pierce the seals B on the container e Place the electrolyte container upside down aligning the six seals with the six battery filler ports e Push the container down strongly enough to break the seals Now the electrolyte should start to flow into the battery NOTE O Do not tilt the container as the electrolyte flow may be interrupted e Make sure air bubbles A are coming up from all six filler ports OLeave the container this way for 5 minutes or longer NOTE no air bubbles are coming up from a filler port tap B the bottom of the bottle two or three times Never remove the container from the battery CAUTION Fill the electrolyte into the battery until the con tainer is completely emptied e Be certain that all the electrolyte has flowed out e Tap the bottom the same way as above if there is any electrolyte left in the container Now pull the container gently out of the battery e Let the battery sit for 20 minutes During this time the electrolyte permeates the special separators and the gas generated b
42. mperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE O The switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switch across the terminals at the temperatures shown in the table If the hand tester does not show the specified values re place the switch Radiator Fan Switch Resistance QhRising temperature From OFF to ON at 96 100 C 205 212 F Falling temperature From ON to OFF at 91 95 C 196 203 F ON Less than 0 5 2 OFF More than 1 MQ ELECTRICAL SYSTEM 16 67 HP14012BS2 C 16 68 ELECTRICAL SYSTEM Switches Coolant Temperature Warning Light Switch Inspection e Remove Coolant Temperature Warning Light Switch see Cooling System chapter e Suspend the switch A in a container of coolant so that the temperature sensing projection and threaded portion are submerged e Suspend an accurate thermometer B in the coolant NOTE The switch and thermometer must not touch the con tainer sides or bottom e Place the container over a source of heat and gradu ally raise the temperature of the coolant while stirring the coolant gently e Using the hand tester measure the internal resistance of the switc
43. nator connector A O Connect a hand tester as shown in the table O Start the engine O Run it at the rpm given in the table O Note the voltage readings total 3 measurements Tester Reading Range Tester to Tester 3 00 250 V AC One yellow lead 36 54 V If the output voltage is within the values the table the alternator is operating correctly and the regulator rectifier is damaged A much lower reading indicates that the al ternator is defective Alternator Output Voltage Check the stator coil resistance as follows O Stop the engine O Disconnect the alternator connector O Connect a hand tester as shown in the table O Note the readings total 3 measurement Stator Coil Resistance Tester Reading Renge Tester Tester to One yellow lead Another yellow lead 0 33 0 49 2 If there is more resistance than shown in the table or no reading infinity for any two leads the stator has an open and must be replaced Much less resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each of the black leads and chassis ground Any reading less than infinity co indicates a short neces sitating stator replacement lf the stator coils have normal resistance but the voltage check shows the alternator to be defective then the rotor magnetism has probably weakene
44. or miss ing Starter jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Crankshaft Sensor trouble Igniter trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Compression release cam K A C R sticks open Engine stalls when moving off Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap shorted or not in good con tact Spark plug incorrect Igniter trouble Pickup coil trouble Ignition coil trouble Battery voltage low Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Starter plunger stuck open Air cleaner clogged poorly sealed or miss ing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Compression low Spark plug loose Cylin
45. out the one way clutch A Starter Motor Clutch Installation e Install the one way clutch so that the flange A fits on the recess B of the race Apply a non permanent locking agent Starter Motor Clutch Bolts e Tighten Torque Starter Motor Clutch Bolts 34 N m 3 5 kgf m 25 ft Ib Starter Motor Clutch Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Fit the starter clutch gear into the starter motor clutch the alternator rotor turns counterclockwise A freely from the starter clutch gear but not clockwise B the clutch is operating correctly the clutch does not operate correctly or if it makes noise disassemble it and examine each part visually Re place any worn or damaged parts NOTE O Examine the starter clutch gear A Replace it if it is worn or damaged 16 54 ELECTRICAL SYSTEM Electric Starter System Torque Limiter Inspection e Remove Alternator Rotor see Alternator Rotor Removal e Remove the torque limiter A and visually inspect it x If the limiter has wear discoloration or other damage replace it as a unit 118022 ELECTRICAL SYSTEM 16 55 Lighting System Headlight Beam Vertical Adjustment e Turn the adjusting screw A on each headlight rim in or out to adjust the headlight vertically NOTE On high beam the brightest point should be slightly be low horizontal with the vehicle on its wheels and the
46. pping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the sealing plug to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Refreshing Charge When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery Year Day Mfg location 16 20 ELECTRICAL SYSTEM Battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced no ticeably if charged under conditions other than given above Never remove the seal caps during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the motorcycle for months Give a refresh charge before you store the motorcycle and store it with the negative lead re moved Give a refresh charge once a month during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has ex ceeded its useful life Replace it Provided however the vehicle s starting system
47. se Lock Cable 4 Clamp 5 Rear Brake Cable 6 Parking Brake Cable HB09059BWN4 C 7 Clamp 8 Band With the Rear Brake Light Switch 9 Through the parking brake cable upper side on the cross pipe 10 Shift Control Cable 11 To Rear Side of Shift Control Grip Cable Wire and Hose Routing s ON Head Light Lead Horn Connector Clamp Clamp Convertor Duct Indicator Unit Lead Connector Rear Brake Switch Lead Connector Front Brake Switch Lead Connector Ignition Switch Lead Connector Left Handlebar Switch Lead Connector APPENDIX 17 19 H809060BW4 C Reverse Power Assist Switch Lead Con nector Clamp Clamp Radiator Fan Connector Ground Tighten with the thermostat cover bolt Water Temperature Warning Switch Lead Radiator Fan Switch Lead 17 20 APPENDIX Cable Wire and Hose Routing 1 Left Head Light Lead Connector 2 Radiator Fan Connector 3 Radiator Fan Switch Connector 4 Water Temperature Warning Switch Lead 5 Ground Tighten with the thermostat cover bolt 6 Clamp H809061BW4 7 Ignition Coil Front 8 Clamp 9 Band 10 Regulator Rectifier 11 Clamp 12 Starter Circuit Relays 13 Clamp APPENDIX 17 21 Cable Wire and Hose Routing NUS 3057 T 809062884 1 To Engine Ground 8 To Regulator Rectifier 2 Main Harness 9 To Reverse Neutral Switch 3 Clamp Main Harness
48. signal to the igniter But when the vehicle banks 60 70 or more to either side in fact falls down the weight turns and shuts off the voltage in the vehicle down sensor circuit The igniter senses this change and stops the fuel pump and the ignition system Hall IC B ELECTRICAL SYSTEM 16 39 HP10001BS1 0617063851 16 40 ELECTRICAL SYSTEM Ignition System 6617036682 C Vehicle down Sensor A Constant Voltage Circuit E Ground Terminal B BK Y Hall IC Integrated Circuit F Output Terminal C Y G Vehicle down Sensor Circuit G Power Source Terminal D BR Front H Vehicle down Sensor Removal CAUTION Never drop the down sensor especially on a hard surface Shock to the sensor can damage it e Remove Rear Fender see Frame chapter Fuel Tank see Fuel System chapter Vehicle down Sensor Lead Connector A Screws B Vehicle down Sensor C Vehicle down Sensor Installation e Install the vehicle down sensor A so that the sensor lead faces backwards B and the arrow mark C on the sen sor points upward e Tighten the screws securely A WARNING Incorrect installation of the vehicle down sensor could cause sudden loss of engine power The rider could lose balance during certain riding situ ations like leaning over in a turn with the potential for an accident resulting in injury or death Ensure that the down sensor is held in place by the sensor brackets ELECTRIC
49. sorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted Brake Doesn t Hold Front brake Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad overworn or worn unevenly Oil grease on pads and disc Disc worn or warped Brake overheated Rear Brake Brake not properly adjusted Plates worn Brake parts worn or damaged Battery Discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wiring faulty Battery Overcharged Regulator rectifier trouble Battery trouble 17 6 APPENDIX Cable Wire and Hose Routing IN 1 7 El Jp 1 Tube 2 Clamp 3 Align the white paint mark on the tube with the adjustment mark on the crankcase 4 Electric Starter APPENDIX 17 7 Cable Wire and Hose Routing 1 Cooling Hoses 2 Clamps Install the clamps with the tabs direction as shown 3 Coolant Valve 4 Position the white marks on the tube as shown 5 Damper 6 Clamps 17 8 APPENDIX Cabl
50. sure the pump is defective Replace the fuel pump 22000851 C Fuel Pump Pressure Standard 17 7 22 6 kPa 0 18 0 23 kgf cm 2 6 3 3 psi Install the fuel pump and tighten it Torque Fuel Pump Mounting Bolts 2 N m 0 2 kgf m 17 in Ib 16 62 ELECTRICAL SYSTEM Fuel Pump Fuel Reserve Switch Fuel Reserve Switch Inspection 1 e Fill the fuel tank with fuel Close the fuel tank cap surely e Remove the fuel tank see Fuel System chapter e Connect the test light A 12 V 3 4 W bulb a socket with leads and the 12 V battery B to the fuel pump connector C Connections Battery gt 12 V 3 4 W Bulb one side 12 V 3 4 W Bulb other side BL Lead Terminal Battery gt BK Y Lead Terminal Special Tool Needle Adapter Set 57001 1457 the test light turn on the reverse switch is defective Replace the fuel pump Fuel Reserve Switch Inspection 2 e Remove Fuel Pump see Fuel System chapter e Connect the test light 12 V 3 4 W bulb in a socket with leads and the 12 V battery to the fuel pump connector as shown 12 V Battery A Test Light B Fuel Pump Connector C Fuel Reserve Switch D x If the test light doesn t light replace the fuel pump NOTE Ot may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed Leave the fuel reserve switch with leads for inspection connected
51. t e Push the bulb in turn it clockwise and release it It should lock in position HP12B051 P ELECTRICAL SYSTEM 16 59 Lighting System Lighting System Circuit HP120088W4 C 1 Reverse Switch 5 Rear Brake Light Switch 11 Main Fuse 30A 2 Reverse Indicator Light 6 Headlight Right 12 Battery LED 7 Headlight Left 13 Tail Brake Light 3 Front Brake Light Switch 8 Reset Connector 4 Parking Brake Light 9 Light Dimmer Switch Switch 10 Ignition Switch 16 60 ELECTRICAL SYSTEM Radiator Fan System Radiator Fan Circuit Inspection e Disconnect the leads from the radiator fan switch A Using an auxiliary wire B connect the radiator fan switch leads lf the fan rotates inspect the fan switch x If the fan does not rotate inspect the following Leads and Connectors Main Fuse and Fan Fuse Fan Motor Radiator Fan Motor Inspection e Disconnect the connector A in the fan lead Using two auxiliary wires supply battery B voltage to the fan motor If the fan does not rotate the fan motor is defective and must be replaced Radiator Fan Motor Leads BL Battery BK Battery Radiator Fan Circuit BL W BL W BL W y 1 Radiator Fan Fuse 20A 2 Radiator Fan Switch 3 Radiator Fan BL AES pee BK gt M gt aa gt S x 4 Main Fuse 30A 5 Battery HP13000BW2 C ELECTRIC
52. ter Blue Red gt Black White lt Black gt e Turn the ignition switch on and rotate the engine for 4 5 seconds with the transmission gear in neutral to measure the pickup coil peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 1 8 V or more the peak voltage is lower than the standard inspect the crankshaft sensor Alternator Rotor Inspection e Check the timing projection A for damage such as chip ping or grooving xIf the timing projection on the rotor is visibly damaged replace the alternator rotor Ignition System Ignition Timing Test e Remove the ignition timing inspection plug e Attach a timing light A and a tachometer in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the timing mark on the alternator rotor e Run the engine at the speeds specified and note the align ment of the timing marks A F or R mark Ignition Timing Engine speed r min rpm Slot B aligned with A 1 100 and below dvanced mark C on alternator otor 5 000 and above i mark D on alternator NOTE O Do not mix up the timing marks with mark A If the ignition timing is incorrect replace the igniter and the crankshaft sensor Vehicle down Sensor Outline This sensor has a weight A with two magnets inside and sends a
53. ter System e Install Starter Motor A Clamp B as shown Starter Motor Cable C e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 in Ib Starter Motor Terminal Nut 4 9 N m 0 50 kgf m 43 in Ib Apply grease to the O ring D in the joint duct E e Install Joint Duct and Collars F Clamp G as shown e Tighten Torque Joint Duct Bolts H 8 8 N m 0 90 kgf m 78 in Ib HP11001BS1 C Starter Motor Disassembly e Remove Starter Motor Bolts A Left End Cover B Right End Cover C Yoke D To remove the brush plate assembly A remove the ter minal nut B ELECTRICAL SYSTEM 16 47 Electric Starter System e Hold the brush spring A with needle nose pliers and pull the brush B off the holder HeTTBOOG Starter Motor Assembly e Replace the O rings e Install the brush plate assembly to the right end cover so that the projection A on the brush plate fits into the groove on the right end cover e Install the O ring insulators B and washer C in that order on the terminal bolt e Tighten Torque Starter Motor Terminal Locknut 6 9 N m 0 70 kgf m 61 in Ib e Install the washers A e Install the armature B between the brushes e Install the yoke A onto the right end cover B aligning the marks C on the yoke and right end cover 16 48 ELECTRICAL SYSTEM Electric Starter System e Install the washers A e Instal
54. tion Be sure all of the old gasket has been removed from the alternator cover and the left crankcase sealing surfaces Check that the dowel pins A are in place and fit a new gasket on the crankcase e Check that the bearing B is in place e Fit the grommets A into the notch in the cover e Grease the alternator cover oil seal e Tighten Torque Alternator Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib ELECTRICAL SYSTEM 16 25 Charging System e Check that the O ring A in the collar B is in good con dition Apply grease to the O ring e Install the collar on the alternator cover e Install the alternator rotor bolt C 9008851 C e Hold the drive pulley with the drive pulley holder A Special Tool Drive Pulley Holder 57001 1520 e Tighten Torque Alternator Rotor Bolt 127 N m 13 kgf m 94 ft Ib Alternator Bolt Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib Add engine oil Alternator Rotor Removal e Remove Alternator Cover see Alternator Cover Removal Ball Bearing A e Thread the flywheel puller A onto the alternator rotor Special Tool Flywheel Puller 57001 1405 e Holding the flywheel puller turn the rotor puller until the alternator rotor is forced off the end of the crankshaft CAUTION If the rotor is difficult to remove turn the puller while tapping the end of the puller Do not strike the alternator rotor Striking the rotor can cause the magn
55. ust be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc De fective wires and bad connections will affect electrical sys tem operation O Measure coil and winding resistance when the part is cold at room temperature O Color Codes BK Black G Green P Pink BL Blue GY Gray PU Purple BR Brown LB Light blue R Red CH Chocolate LG Lightgreen W White DG Darkgreen Orange Y Yellow Precautions O Electrical Connectors Female Connectors A Male Connectors B ELECTRICAL SYSTEM 16 15 6208010251 16 16 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x lf any wiring is defective replace the damaged wiring e Pull each connector A apart and inspect for corrosion dirt and damage If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity O Use the wiring diagram to find the ends of the lead which is suspected of being a problem O Connect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 Set the tester to the 1 range lf the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary Q HPO70008S1 C Battery ELECT
56. ve measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise x lf the arcing distance is as before the trouble is with the ignition coil If the arcing distance is normal the trouble is with the spark plug cap x If a coil tester is not available the coil can be checked for a broken or badly shorted winding with a hand tester Special Tool Hand Tester 57001 1394 NOTE O The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage 10016851 C 10008852 C Ignition System Measure the primary winding resistance A as follows O Connect the tester between the coil terminals Set the tester to the x 1 range e Measure the secondary winding resistance B as follows O Remove the plug cap by turning it counterclockwise O Connect the tester between the spark plug lead and ter minal Set the tester to the x 1 range Ignition Coil Winding Resistance Primary windings 0 09 0 13 Q Secondary windings 3 8 5 8 the hand tester does not read as specified replace the coil O To install the plug cap turn it clockwise ELECTRICAL SYSTEM 16 35 10009851 16 36 ELECTRICAL SYSTEM Ignition System Ignition Coil Primary Peak Voltage Inspection NOTE O Be sure the battery is fully charged e Remove the spark plug cap see Spark Plug R
57. worn Shift fork worn Shift shaft spring weak or broken Shift control cable maladjusted Drive shaft output shaft and or gear splines worn Overshifts Shift shaft spring weak or broken Shift control cable maladjusted Abnormal Engine Noise Knocking Igniter trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain sprocket guides worn Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Driven pulley shoe worn Drive pulley weight or roller side washer worn Troubleshooting Guide Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insu
58. y chemical reaction is released 6208030451 C ELECTRICAL SYSTEM 16 19 Battery e Fitthe seal caps A tightly into the filler ports until the seal caps are at the same level as the top of the battery NOTE O Do not hammer Press down evenly with both hands CAUTION Once you installed the seal caps after filling the bat tery never remove it nor add any water or elec trolyte 6 08012851 6208010851 C Initial Charge While an sealed battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of higher than 12 6 V after 10 minutes of filling Note 1 no initial charge is necessary Charging method 1 4A x2 hours Condition requiring initial charge At low temperatures lower than 0 C Battery has been stored in high temperature and humidity Seal has been removed or broken peeling tear or hole If you did not hear the air sucking sound Shoosh as you removed the seal Battery as old as 2 years or more after manufacture es pex ions Battery manufacturing date is printed on battery top Example 12 10 99 1 Month Note 1 Terminal voltage To measure battery terminal voltage use a digital voltmeter Precautions 1 No need of to
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