Battery Repair Ebook

EZ Battery Reconditioning Method

This eBook guide gives you all the information that you need to know to never have to buy batteries again. You will learn what it takes to recondition your batteries that you already have, with things that already have at your house or can easily get. You can save money by never having to buy batteries again But it gets better! You can make huge profits off of selling the batteries that you reconditioned at premium prices. You don't have to have any technical know-how to learn how to do this All it takes is the information in this book! No matter what kind of batteries they are Even if they are car batteries, normal AA batteries, or forklift batteries, you can recondition them like new and sell them at full price or reuse them for yourself! More here...

EZ Battery Reconditioning Method Overview

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Author: Tom Ericson
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My EZ Battery Reconditioning Method Review

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Battery Charging

Turn the power ON OFF at the charger, not at the battery terminals Clean the battery terminals and position the battery as far away from the charger as the leads will permit. Christie battery charger 3. Set the TIMER to the position indicated by the Honda Battery Tester RED-3, RED-2 or YELLOW 1. If you are charging a new battery, set the switch to the NEW BATT position. 4. Attach the clamps to the battery terminals red to positive, black to negative.

Technical Information Maintenance Free Battery

A lead-acid battery operates under the following chemical reaction Normally in an ordinary lead-acid battery when it comes to an end of a charge, where the lead sulfate being a discharge product returns to lead peroxide and spongy lead, the charge current flowing thereafter is used exclusively to decompose electrolytically water from the electrolyte, thus resulting in generation of hydrogen gas from the negative plate and oxygen gas from the positive plate. The gases so generated are released out of the battery, causing the amount of electrolyte decreased to require occasional water replenishment.

Neutral indicator light

6 If the neutral light fails to operate when the transmission is in Neutral, check the fuse and the bulb (see Section 23 for bulb removal procedures). If the bulb and fuse are in good condition, check for battery voltage at the connector attached to the gearshift sensor. Remove the fairing lower cover from the right side of the bike follow the wiring harness from the grommet at the top of the front engine cover to the connector. If battery voltage is present, refer to Section 18 for the gearshift

Removal and installationsk

8 Trace the wiring from the EXUP system servo motor and disconnect it at the connectors (see illustration). Using a fully charged 12V battery and some jumper leads, connect the positive (+ve) terminal of the battery to the black yellow wire terminal on the servo side of the connector, and the negative (-ve) terminal to the black red wire terminal. When the battery is connected, the servo should operate. Disconnect the battery immediately after the test. black red wire terminal on the loom side of the connector, and the negative (-ve) terminal to the black yellow wire terminal. Battery voltage should be present. If not, check the connector for loose or corroded terminals, then check the fuse and the battery, and then the wiring between the connector and the ignition control unit, referring to the test procedures and Wiring Diagrams in Chapter 9.

Description Of System

The generating system consists of the 6-volt, shunt-wound, third-brush and lamp-load regulated generator, the storage battery and the relay. One of the two field coils (shunt coil) is controlled by the lighting circuit to increase the current output when either the running service light or the blackout light are turned on. The ignition-light switch cuts in the field shunt coil for the service light, and a magnetic field switch cuts in the field shunt coil for the blackout light. Maximum charge rate of 4 amperes (with service light on) is sufficient to keep the battery in a good state of charge under normal service conditions.

Troubleshooting procedure

40 If the lights have not come on, remove the fairing (see Chapter 8). Disconnect the instrument cluster wiring connectors. Using a voltmeter, connect the positive (+) probe to the black wire terminal on the loom side of the 6-pin connector and the negative (-) probe to the green wire terminal on the loom side of the 9-pin connector. With the ignition ON there should be battery voltage. If voltage is

Stripping Motorcycle For Transmission Repair

Remove battery ground wire and battery. Remove foot shifter lever and cover plate. Remove chain housing cover. Remove compensating sprocket nut. 3. Remove mainshatt key. Loosen the tive transmission base mounting nuts. Remove the four bolts attaching chain housing to engine crankcase and four bolts attaching housing to transmission. Remove the two chain housing stud nuts attaching starter housing to chain guard. Remove wires connected to starter solenoid terminals. Pull inner chain housing loose from mainshaft using Puller, Part No. 95960-41 A, which has four screws to fit tapped holes in chain housing. Care must be taken to be sure housing moves out squarely as front end is snug fit on shoulder of crankcase. As housing is pulled out, shake starter assembly shaft to free it from gear in starter motor housing. Remove chain oiler hose at oil pump. Remove chain housing oil return hose at rear of chain quard and vent host at T-con-nection and move housing away. On FX, remove foot shifter...

Battery Is Damaged Or Weak

Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER BM210 or BATTERY MATE or equivalent Measure and record the battery voltage using a digital multimeter (page 17-5). Start the engine. Measured battery Voltage < Measured charging voltage < 15.5 V Is the measured charging voltage within the standard voltage

Glide Sportster Servicar

If the horn does not blow satisfactorily, the trouble may be caused by a constricted diaphragm, loose terminal wires, or a discharged battery. Before attempting to correct horn performance by moving the adjusting screw, it is recommended procedure to trouble shoot as follows (Fig. 5K-1 and 5K-2).

Technical Terms Explained ref43

Rebound damping A means of controlling the oscillation of a suspension unit spring after it has been compressed. Resists the spring's natural tendency to bounce back after being compressed. Rectifier Device for converting the ac output of an alternator into dc for battery charging. Reed valve An induction system commonly used on two-stroke engines. Regulator Device for maintaining the charging voltage from the generator or alternator within a specified range.

Poor Running or No Power at High Speed Firing incorrect

Spark plug dirty, broken, or maladjusted Spark plug incorrect IC igniter in ECU trouble Muffler overheating For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest service facility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper cables, and start the engine using the electric starter) For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle with the ignition switch off (Turn the ignition switch ON and run the engine) IC igniter in ECU trouble Fuel air mixture incorrect Throttle body assy holder loose Air cleaner duct loose Air cleaner poorly sealed, or missing

Table of Contents

Battery Regulator rectifier output voltage Battery voltage to 14 - 15 V Night, 4,000 r min (rpm) Stator coil resistance 0.34 - 0.52 i2 0D0 not reverse the battery lead connections. This will burn out the diodes in the electrical parts. oAlways check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. oWhen the level of the electrolyte in the battery is low, add only distilled water to each cell, until the level is at the upper level line marked on the outside of the battery. Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery, oNever add sulphuric acid solution to the battery. This will make the electrolyte solution too strong and will ruin the battery within a very short time. oAvoid quick-charging the battery. A quick-charge will damage the battery plates. oNever let a good battery stand for more than 30 days without giving it a...

XRV750L to N 1990 to 1992 models

2 If all is good so far, disconnect the wiring connector from the circuit checker, located below the instrument cluster on the right-hand side. With the ignition switch ON. check for battery voltage between the black (+) and green white (-) wire terminals on the connector. There should be battery voltage. If not, check the wiring and connectors for faults, referring to the Wiring Diagrams at the beginning of the Chapter. If there is voltage, the checker is faulty and must be replaced with a new one.

Check and replacement

Tachometer Africa Twin

8 On H to R (1987 to 1995) models with three wires to the tachometer, disconnect the cluster wiring connectors, then check for battery voltage between the black (+) wire terminal on the loom side of the connector and a good earth (ground) with the ignition switch ON. If there is no voltage, check the wiring and connectors for faults, referring to the relevant Wiring Diagram at the end of the Chapter. If there is voltage, check for continuity to earth in the green wire, and for continuity to the ignition control unit in the black yellow wire, again using the Wiring Diagrams. Otherwise, take the tachometer to a Honda dealer for assessment. 21 First check the fuses (see Chapter 5), If they are good, remove the fairing (see Chapter 8) and disconnect the instrument cluster wiring connectors (see illustration 15.3b). Check for battery voltage between the brown (+) and green black (-) wire terminals with the ignition switch ON. If there is no voltage, check the wiring and connectors for...

How To Remove Honda Xrv750 Africa Twin Battery

Honda Cbr400rr Wir

1 The battery provides power for operation of the headlight, tail light, brake light and instrument cluster lights. If none of the lights operate, check the battery first, making sure the terminals are clean and secure and the voltage level is sufficient. Low battery voltage indicates either a neglected or faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 30 and 31 for charging system tests. Also, check the fuses. Note that if there is more than one problem at the same time, it is likely to be a 2 If a headlight beam fails to work, first check the fuse (see Section 5), and then the bulb(s) (see Section 7). If they are good, use jumper wires to connect the bulb in question directly to the battery terminals. If the light comes on, the problem lies in the wiring or connectors, the switches in the circuit, or the relay(s) (XRV750 models). Alternatively the bulb can be checked for continuity using a multimeter. Refer to Section 20 for the...

Illus 99 Cutout Relay

A low battery and a low or no generator charging rate indicates a high resistance in charging circuit, or regulator or generator is faulty. Care of Storage Battery 1. Inspect battery every week. Add pure distilled water as often as necessary to keep solution above the plates. See Adding Water to Battery, Page 107. 2. Remove battery and have it given a charge from an outside source, when the hydrometer shows that this attention is needed. Allowing battery to remain in a discharged condition for any length of time shortens its life. A fully charged battery has a specific gravity reading of 1.275 or above a discharged battery has a specific gravity reading of about 1.150. It is especially important that battery be kept well charged in below freezing weather as a low or discharged battery is very likely to be frozen and ruined. When charging a battery from an outside source, the charging rate is constant and should not be allowed to go over 2 amperes. A higher rate will heat and damage...

Removal and installation

Next check for battery voltage at the yellow red wire when the starter button is pressed. If there is no voltage, check the wiring between the relay wiring connector and the starter button. If voltage is present, check that there is continuity to earth in the green red wire with the transmission in neutral, the clutch lever pulled in and the sidestand up (note that there will be a very slight resistance due to the diode). If there is no continuity, check the other components in the starter circuit as described in the relevant sections of this Chapter. If all components are good, check the wiring between the various components (see the wiring diagrams at the end of this book). 8 Disconnect the battery terminals, remembering to disconnect the negative (-) terminal first.

Check and replacementSk

4 If the switches are good, check for voltage at the black wire terminal on the connector with the ignition switch ON - there should be battery voltage. If there's no voltage present, check the wiring between the switch and the ignition switch via the fusebox (see the Wiring Diagrams at the end of this Chapter). II voltage is present, check the green yellow wire for continuity to the brake light bulb wiring connector, referring to the relevant Wiring Diagram. Repair or renew the wiring as necessary.

REF42 Fault Finding Equipment

2 If using a meter, check first that the meter leads are plugged into the correct terminals on the meter (see above). Set the meter to the dc volts function, at a range suitable for the battery voltage. Connect the meter red probe (+ve) to the power supply wire and the black probe to a good metal earth (ground) on the motorcycle's frame or directly to the battery negative (-ve) terminal (see illustration 14). Battery voltage should be shown on the meter

REF46 Technical Terms Explained

Rebound damping A means of controlling the oscillation of a suspension unit spring after it has been compressed. Resists the spring's natural tendency to bounce back after being compressed. Rectifier Device for converting the ac output of an alternator into dc for battery charging. Reed valve An induction system commonly used on two-stroke engines. Regulator Device for maintaining the charging voltage from the generator or alternator within a specified range. Spalling Damage to camshaft lobes or bearing journals shown as pitting of the working surface. Specific gravity (SG) The state of charge of the electrolyte In a lead-acid battery. A measure of the electrolyte's density compared with water. Straight-cut gears Common type gear used on gearbox shafts and for oil pump and water pump drives. lead-acid battery. Poisonous and extremely

Zr550 Loose Yellow Black Wire

Motorcycle Relay Checking

Apply battery voltage directly to the terminals on the horn. If the horn sounds, check the switch (see Section 21) and the wiring between the switch and the horn (see the wiring diagrams at the end of this Chapter). lead terminals. Using a fully-charged 12 volt battery and two insulated jumper wires, connect the positive (+) terminal of the battery to the yellow red wire terminal of the relay, and the negative (-) terminal to the black yellow wire terminal of the relay (see illustration). At this point the relay should click and the multimeter read 0 ohms (continuity). If this is the case the relay is proved good. If the relay does not click when battery voltage is applied and indicates no continuity (infinite resistance) across its terminals, it is faulty and must be replaced. 5 If the relay is good, check for battery voltage between the yellow red wire and the black yellow wire when the starter button is pressed. Check the other components in the starter circuit as described in the...

How To Change Headlight Bulb On Gsf600

1 The battery provides power for operation of the turn signal lights, so if they do not operate, a ways check the battery voltage first. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 32 and 33 for charging system tests. Also, check the fuse (see Section 5) and the switch (see Section 20).

Motorcycle Headlight And Sidelight Wiring

1 The battery provides power for operation of the turn signal lights, so if they do not operate, always check the battery voltage first. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 30 and 31 for charging system tests. Also, check the tail signal fuse (see Section 5) and the switch (see Section 20).

Steps For Replacing Icu In Honda Motorcycle

41 If the lights have come on, remove the left-hand side panel (see Chapter 8). Disconnect the ICU 22-pin wiring connector. Using a voltmeter, connect the positive (+ve) probe to the white red wire terminal on the loom side of the indicator connector and the negative (-ve) probe to earth (ground). Turn the ignition ON - there should be battery voltage. 42 If there was no voltage, using a voltmeter, connect the positive (+) probe to the white red wire terminal on the loom side of the indicator connector and the negative (-) probe to the green wire terminal on the loom side of the instrument cluster connector. Turn the ignition ON - there should be no voltage for two seconds, then there should be battery voltage. If there is no voltage after two seconds, check for continuity in the wiring, referring to the Wiring Diagrams at the end of Chapter 9. The green wire goes to earth (ground). If no voltage is present, the indicator unit is faulty and must be replaced with a new one (see Chapter...

Yamaha Yzf750r Fuel Pump Torque Settings

4 To check the operation of the relay, connect a meter set to the ohms x 100 range, or a continuity tester, between the blue and blue white wire terminals of the relay. No continuity should be shown. Now using jumper wires connect a fully charged 12V battery to the relay's black yellow and red black wire terminals (positive (+ve) lead to red black and negative (-ve) lead to black yellow). The meter should show continuity with battery voltage applied. 3 Unplug the wiring connectors from the horn (see illustrations). Using two jumper wires, apply battery voltage directly to the terminals on the horn. If the horn sounds, check the switch (see Section 19) and the wiring between the switch and the horn (see Wiring Diagrams at the end of this Chapter). 4 Set a multimeter to the ohms x 1 scale and connect it across the relay's starter motor and battery lead terminals (marked 'M' and 'B' respectively) (see illustration 27.2c). Using a fully-charged 12 volt battery and two insulated jumper...

Poor running at idle and low speed

In certain conditions low battery charge, especially when coupled with a badly sulphated battery, may result in misfiring. If the battery is in good general condition it should be recharged an old battery suffering from sulphated plates should be renewed.

Technical Terms Explained ref

Allen key A hexagonal wrench which fits into a recessed hexagonal hole. Alternating current (ac) Current produced by an alternator. Requires converting to direct current by a rectifier for charging purposes. Alternator Converts mechanical energy from the engine into electrical energy to charge the battery and power the electrical system. Ampere (amp) A unit of measurement for the flow of electrical current. Current Volts Ohms. Ampere-hour (Ah) Measure of battery capacity. Angle-tightening A torque expressed in degrees. Often follows a conventional tightening torque for cylinder head or main bearing fasteners (see illustration).

Clutch Troubleshooting

Headlight comes on, but goes out when the starter button is pushed There may be a bad connection at the battery. Wiggle the battery terminals and re-check. If the starter starts cranking, you've found the problem. Remove and clean the battery terminal clamps. Clean the battery posts also. Reinstall the terminal clamps and tighten securely.

Installationconnection

Attach the cables to the correct battery terminals using the proper torque. Overtightening bolts can damage battery terminals and incorrect connections may damage the motorcycle's electrical system. The electrolyte in a discharged battery will freeze if exposed to freezing temperatures. Freezing may crack the battery case and buckle battery plates. The BATTERY TENDER PLUS AUTOMATIC BATTERY CHARGER (Part No. 99863-93TA) may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling.

Headlight Adjustment Suzuki Gsx1100f

1 The battery provides power for operation of the signal lights, so if they do not operate, always check the battery voltage and specific gravity first. Low battery voltage indicates either a faulty battery, low electrolyte level or a defective charging system. Refer to Chapter 1 for battery checks and Section 26 for charging system tests. Also, check the fuses (see Section 5).

Getting back on the road

Use a suitable battery charger - this kit also assess battery condition On conventional refillable batteries, if the battery has not received any attention, remove it from the motorcycle and check its electrolyte level. Top up if necessary then charge the battery. If the battery fails to hold a charge and a visual checks show heavy white sulphation of the plates, the battery is probably defective and must be renewed. This is particularly likely if the battery is old. Confirm battery condition with a specific gravity check. Battery voltage low. Check and recharge battery (Chapter 9). Battery voltage low. Check and recharge the battery as necessary (Chapter 9).

License plate light Interstate and Aspencade

1 The battery providos power for operation of the signal lights, so if they do not operate, always check the battery voltage and specific gravity first. Low battery voltage indicates either a faulty battery, low electrolyte level or a defective charging system. Refer to Chapter 1 for battery checks and Sections 28 and 29 for charging system tests.

Function Of Regulator

When the engine r min becomes higher, the generated voltage of the generator also becomes higher and the voltage between the battery terminals becomes high accordingly. When it reaches the adjusted voltage of the I.C., (Integrated Circuit) and it is turned ON, a signal will be sent to the SCR (Thyristor) gate probe and the SCR will be turned ON.

Testing Cutout Relay Unit Closing Voltage

As resistance is decreased in field circuit, voltage will rise. Note highest reading before meter pointer kicks to read battery voltage. Repeat operation several times, each time turning field control to Open position. Highest reading observed is the cutout relay closing voltage.

REFMo Fault Finding Equipment

Measuring open-circuit battery voltage Measuring open-circuit battery voltage You'll need a dc voltmeter or multimeter to check battery voltage. Check that the leads are inserted in the correct terminals on the meter, red lead to positive (+ve), black lead to negative (-ve). Incorrect connections can damage the meter. 1 Set a multimeter to the 0 to 20 volts dc range and connect its probes across the battery terminals. Connect the meter's positive (+ve) probe, usually red, to the battery positive (+ve) terminal, followed by the meter's negative (-ve) probe, usually black, to the battery negative terminal (-ve) (see illustration 4). 2 If battery voltage is low (below 10 volts on a 12 volt battery or below 4 volts on a six volt battery), charge the battery and test the voltage again. If the battery repeatedly goes flat, investigate the motorcycle's charging system. Battery-powered continuity tester

Coolant Temperature Gauge

The temperature gauge needle should move all the way to H and battery voltage should register. If battery voltage registers, but the temperature gauge does not move, replace the thermosensor. If the battery voltage does not register, check the connectors for a loose or blown fuse. If battery voltage does not register, there is an open circuit

Relay Adjustment And Repair

The relay is provided with an additional contact for the normally open position to control the signal light in the instrument panel. When the generator voltage exceeds the battery voltage (between 6.3 and 6.8 volts) the relay closes the battery-generator circuit. At this time, the upper contact points break and the panel green indicator light goes off, indicating that the generator is charging the battery. This occurs at approximately 20 miles per hour in high gear.

Overhauling Transmission And Clutch

Remove battery box as follows Disconnect battery terminal wires and remove battery. Loosen two nuts securing rear safety guard center connection to mounting studs. Unscrew mounting studs to free plate clamping battery box bracket to frame. Remove battery box front bolt and two rear bottom bolts. Remove battery box from left side of frame.

Initial Charge

4) Battery life Keep the battery away from sparfcs 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 sparfcs 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 loosened.

Testing

Hydrometer testing is the best way to check battery condition. Use a hydrometer with numbered graduations from 1.100 to 1.300 rather than one with color-coded bands. To use the hydrometer, squeeze the rubber ball, insert the tip into the cell and release the pressure on the ball. Draw enough electrolyte to float the weighted float inside the hydrometer. Note the number in line with the surface of the electrolyte this is the specific gravity for this cell. Squeeze the rubber ball again and return the electrolyte to the cell from which it came.

Engine

Loose wire connection at one of battery terminals, or at coil or circuit breaker. 9. Loose wire connection at one of battery terminals, or at coil or circuit breaker. 2. Discharged battery, or loose or corroded connections. 4. Discharged battery or loose or broken battery terminal connection. Check by turning light switch ON. 9. Loose wire connection at one of battery terminals, or at coil or circuit breaker.

Description

The electric starting system requires a fully charged battery to provide the large amount of current required to operate the starter motor. The alternator and a voltage regulator rectifier, connected in circuit with the battery, keep the battery charged while the engine is running. The battery can also be charged externally.

Leakage test

3 Set the multimeter to the mA (milliamps) function and connect its negative probe to the battery negative terminal, and the positive probe to the disconnected negative cable (see illustration). Caution Don't connect the ammeter between the battery terminals or the ammeter will be ruined. Compare the reading to the value listed in this Chapter's Specifications.

Servicing

Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpaper.

Electrical problems

Battery life should not be expected to exceed 3 to 4 years, particularly where a starter motor is used regularly. Gradual sulphation of the plates and sediment deposits will reduce the battery performance. Plate and insulator damage can often occur as a result of vibration. Complete power failure, or intermittent failure, may be due to a broken battery terminal. Lack of electrolyte will prevent the battery maintaining charge.

Alternator

The alternator is a form of electrical generator in which a magnetized field called a rotor revolves around a set of stationary coils called a stator assembly. As the rotor revolves, alternating current is induced in the stator coils. The current is then rectified to direct current and is used to operate the electrical systems on the motorcycle and to keep the battery charged. The rotor is permanently magnetized.

Charger

5 Check the battery terminals and leads for tightness and corrosion. If corrosion is evident, unscrew the terminal screws and disconnect the leads from the battery, disconnecting the negative (-) terminal first, and clean the terminals and lead ends with a wire brush or knife and emery paper. Reconnect the leads, connecting the negative (-) terminal last, and apply a thin coat of petroleum jelly to the connections to slow further corrosion. 8 If the motorcycle sits unused for long periods of time, disconnect the cables from the battery terminals, negative (-) terminal first. Refer to Section 4 and charge the battery once every month to six weeks. 9 The condition of the battery can be assessed by measuring the voltage present at the battery terminals. Connect the voltmeter positive (+) probe to the battery positive (+) terminal and the negative (-) probe to the battery negative (-) terminal. When fully charged there should be more than 12.5 volts present. If the voltage falls below...

Ammeter

4.4 If the charger doesn't have ammeter built in, connect one in series as shown. DO NOT connect the ammeter between the battery terminals or it will be ruined 5 If the recharged battery discharges rapidly if left disconnected it is likely that an internal short caused by physical damage or sulphation has occurred. A new battery will be required. A sound item will tend to lose its charge at about 1 per day.

Troubleshooting

Disengage spark plug cable and insert a metal rod, screwor nail into each spark plug cable. Arrange cable end so tip of inserted metal object is 1 4 in. away from cylinder head. Turn on the ignition, break the points by hand. See if a hot of blue spark is obtained. If not, it is an indication of a weak coil, dead battery, broken or loose wires, etc. Arcing of the points and hard starting indicates a faulty condenser.

Charging Battery

To determine the amount or condition of a battery charge, check solution in each cell with a battery hydrometer. When hydrometer reading is 1.200 or less, battery is considered discharged and should be removed from motorcycle and charged at the following maximum continuous charge rate using appropriate 6 or 12 volt charger. A higher battery charge rate will heat and damage the battery. For this reason, do not allow the small motorcycle battery to be charged in the same line with large batteries. Hydrometer reading of a fully charged battery in good condition, with full strength electrolyte will be 1.270 or higher.

Changing Electrolyte

The value of changing electrolyte in a fairly old battery is questionable. By tipping over such a battery to drain the solution, the sloughed-off waste materials accumulated by repeated charging and discharging actions might be dislodged from the sediment chambers in the bottom of the battery and deposited in the separators. This material is an electrical conductor and thus may tree or catch in the separators and cause a short circuit.

Fan Motor Switch

The fan motor should turn and battery voltage should be measured. If the battery voltage is measured, but the fan motor does not turn, replace the fan motor. If the fan motor does not turn and battery voltage does not register, check that battery voltage is measured between Black Blue and Green terminal at the wire harness side on the 2P black connector. If there is no battery voltage, check for a blown fuse, loose connector, or an open circuit in the wire. If there is voltage, inspect the fan motor switch as follows Remove the switch.

Adjustment

If the horn fails to blow or does not blow satisfactorily, check for loose, frayed or damaged wiring leading to horn terminals, discharged battery, etc. If these steps do not correct the trouble, turn the contact point adjuster screw located back of horn until horn just gives a single click - then retard screw until best tone is obtained. If horn fails to operate after moving adjusting screw it is necessary to disassemble horn for inspection and cleaning of parts.

Assembly

Horns are shown in Figures 5K-4, 5K-5, and 5K-6. If the horn fails to blow or does not blow satisfactorily, check for loose, frayed or damaged wiring leading to horn terminals, discharged battery, etc. If these steps do not correct the trouble, turn in contact point adjusting screw, located back of horn, until horn just gives a single click - then retard screw until best tone is obtained. If horn fails to operate after moving adjusting screw, entire horn must be replaced because it is permanently riveted together. Mounting parts are replaceable.

Locating Troubles

If the connections and wiring are found to be satisfactory, the battery should be checked to determine its state of charge (See Section 5J, Charging Battery) . If the battery is charged and battery voltage is reaching the motor without any excessive losses in wiring or connections, the trouble may be attributed to either the engine or the starter motor itself.

Kawasaki 57001-1099

7 Connect a multimeter set to the 0-20 volts dc scale (voltmeter) across the terminals of the battery (positive (+) lead to battery positive (+) terminal, negative (-) lead to battery negative (-) terminal). Start the engine, then turn on the lights (UK models) and note the reading obtained at idle speed - it should be just under battery voltage (12V). Increase engine speed and note the voltage reading - it should vary between 14 to 15V. Stop the engine and disconnect the meter when testing is complete. If the voltage is outside these limits, check the unregulated output of the alternator (see below), and the regulator (see Section 35). Note If the voltage is low, it is more likely that the alternator is faulty. If the voltage is above 15 volts, it is more likely that the regulator is faulty.

Tread Depth

If the battery voltage is 13.0-13.2 volts (at 20 C 68 F), the battery is fully charged b. If the battery voltage is below 12.3 volts (at 20 C 68 F ), the battery is undercharged and requires charging. c. If the battery voltage is less than 12.0 volts (at 20 C 68 F ), the battery is unserviceable and must be replaced. 9. If the battery is undercharged, recharge it as described in this chapter. Then test the charging system as described in Chapter Two.

Battery Testing

The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100 fully charged condition. If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then re-check the voltage after the battery has set for one to two hours. BATTERY CHARGE CONDITIONS

Trouble Chart Engine

Loose wire connection at one of battery terminals or at coil or circuit breaker. 9. Loose wire connection at one of battery terminals or at coil or circuit breaker. 4. Discharged battery or loose or broken battery terminal connection. Check by turning light switch ON. 9. Loose wire connection at one of battery terminals or at coil or circuit breaker.

Specifications

Loosen the five transmission base mounting nuts. Remove the four bolts attaching chain housing to engine crankcase and four bolts attaching housing to transmission. Remove the two chain housing stud nuts attaching starter housing to chain guard. Remove wires connected to starter solenoid terminals. Pull inner chain housing loose from mainshaft. Care must be taken to be sure housing moves out squarely as front end is snug fit on shoulder of crankcase. As housing is pulled out, shake starter assembly shaft to free it from gear in starter motor housing. Remove chain oiler hose at oil pump. Remove chain housing oil return hose at rear of chain guard, vent hose at T-connection and move housing away. On FX, remove foot shifter lever linkage from chain housing and shifter pawl lever on transmission cover. Remove battery carrier bracket from right side of transmission. Remove right passenger footrest bracket. Remove starter motor bracket and pull starter motor out left...

Cooling fan switch

11 If the fuse Is good, on XL600V and XRV750 models remove the right-hand fairing side panel, and on XL650V models remove the (airing (see Chapter 8). Disconnect the wiring connector from the fan switch on the radiator (see illustration 3.3b). Using a jumper wire if necessary, connect the wire to earth (ground). Turn the ignition switch ON. The fan should come on. If ft does, the fan switch is defective and must be replaced with a new one. If it does not come on, check for battery voltage at the switch wiring connector with the ignition ON. If voltage is present, test the fan motor itself (see above). If there is no voltage, check the wiring and connectors for a fault or break.

Cooling fan

2 If the fan does not come on (and the fan switch is good), the fault lies in either the cooling fan motor or the relevant wiring. Test all the wiring and connections as described in Chapter 9, following the relevant Wiring Diagram. Disconnect the fan wiling connector and check that there is battery voltage at the black blue or blue black (according to model) wire terminal on the loom side of the connector with the ignition ON. If there is no voltage, check the wiring.

Charging

After the battery has been charged for the pre-determined time, turn the charger off, disconnect the leads and measure the battery voltage. Refer to the following a. If the battery voltage is 13.0-13.2 volts (at 20 C 68 F ), the battery is fully chargcd. b. If the battery voltage is below 12.3 volts (at 20 C 68 F ), the battery is undercharged and requires charging. New Battery Installation When replacing the old battery with a new one, charge it completely before installing it in the bike. Failure to do will reduce the life of the battery. Using a new battery without an initial charge will cause permanent battery damage. That is, the battery will never be able to hold more than an 80 charge. Charging a new battery after it has been used will not bring its charge to 100 . When purchasing a new battery from a dealership or parts store, verify its charge status. If necessary, have them perform the initial or booster charge before picking up the battery. Recycle your old battery. When...

Ignition Coil

The ignition coil is a pulse type transformer that transforms or steps up low battery voltage to the high voltage necessary to jump the electrode at the spark plug in the cylinder head. Internally the coil consists of primary and secondary windings with a laminated iron core and sealed in waterproof insulating compound. The ignition coil cannot be taken apart or coil repaired. If the ignition coil is defective, it must be replaced.

H28946

None of the lights operate, always check battery voltage before proceeding. Low battery voltage indicates either a faulty battery, low battery electrolyte level or a defective charging system. Refer to Chapter 1 for battery checks and Section 26 for charging I system tests. Also, check the condition of the fuses (and circuit breaker, if equipped), j Replace any blown fuses with new ones or reset the circuit breaker if its red button has popped out. 2 If the headlight is out when the engine is running (US and Canadian models) or won't come on (UK models), check the fuse first with the key On (see Section 5), then unplug the electrical connector for the headlight and use jumper wires to connect the bulb directly to the battery terminals. If the light comes on, the problem lies in the wiring or one of the switches in the circuit. Refer to Section 17 for the switch testing procedures, and also the wiring diagrams at the end of this Chapter. 3 If the taillight fails to work, check the...

Final drive oil

8 If the specific gravity is low, the battery is not fuHy charged. This may be due to corroded battery terminals, a dirty battery case, a malfunctioning charging system, or loose or corroded wiring connections. On the other hand, it may be that the battery is worn out, especially f the machine is old, or that infrequent use of the motorcycle prevents normal charging from taking place.

Lighting System

The battery provides power for operation of the headlight, taillight, license light, and meter lights. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or a defective charging system. See CHARGING SYSTEM for checks of the battery and charging system. Also check fuse condition. Replace any open fuses. There are individual fuses for various circuits (see the complete circuit diagram). Check for battery voltage (12V) on brown lead to fuse HEAD Check for battery voltage (12V) on red yellow Check for battery voltage (12V) on blue black lead Check for battery voltage at Check for battery voltage at headlight high beam or low beam terminal HIGH Yellow lead LOW Green lead

Repair Procedure

Clean engine thoroughly with Gunk to remove all road dirt. Remove Gunk and dirt with water spray and blow engine dry with compressed air. Drain gasoline and oil. Remove battery cover and disconnect battery cables Disconnect hoses from carburetor and remove bolts securing gasoline tank. Tank can then be removed from motorcycle. 23. Remove battery (23), battery carrier (24). and oil tank

Sun Vat26 Tester

Testing Battery Capacity CHARGING BATTERY Figure 5-25. Testing Battery Capacity CHARGING BATTERY To determine the amount or condition of a battery charge, check solution in each cell with a battery hydrometer or individual cell voltage with a voltmeter as outlined in paragraph titled Testing Battery, above. When hydrometer reading is 1.200 or less, battery is considered discharged and should be removed from motorcycle and charged at the following maximum continuous charge rate using appropriate 12 volt charger. A higher battery charge rate will heat and damage the battery. For this reason, do not allow the small motorcycle battery to be charged in the same line with large batteries. Hydrometer reading of a fully charged battery in good condi -tion, with full strength electrolyte will be 1.270 or higher.

Low Fuel Indicator

Check for battery voltage between the fuel level sensor connector terminals. I Battery voltage exists No battery voltage 1. Check for battery voltage between the fuel level sensor connector terminals. I No battery voltage Battery voltage 2. Check for battery voltage between the battery side of the wire from the indicator light and ground. No battery voltage Battery voltage

Oil Pressure Switch

The oil pressure warning light should come on and battery voltage should be measured. If the battery voltage is present, but oil pressure warning light does not come on, replace the oil pressure switch. If the battery voltage is not measured and the oil pressure warning light does not come on, check the connectors for loose connection and check for a blown fuse or burnt out bulb. If the battery voltage is not measured, there is an open

Electrical System

Two styles of generators were used on 1966-1969 models. These were the standard (Figure 1) and fan-cooled (Figure 2) generators. The standard generator is a two-pole direct current two-brush unit. A voltage regulator controls the generator charging rate. When the battery charge is low or when current is used, the voltage regulator increases the generator charging rate. The charging rate decreases when the battery is near or at full charge and no current is being used.

Battery Descriptions

There are two types of batteries used in Handa motorcycles, scootors and ATVs the conventional battery and the Maintenance free battery. THE STRUCTURE Of A CONVENTIONAL BATTERY Conventional Battery Since the specific gravity of the electrolyte (relative weight of sulphuric acid as compared with an equal volume of water) varies, the battery state of charge is determined by measuring the electrolyte's Specific gravity. When you charge the lead.'acid battery, electro lysis breaks the water down into its components, hydrogen end oxygen. Because of the generation of those gases, you must remove the filler plugs while charging the battery. The battery is said to be overcharged when an excess current is supplied to the battery, When the battery is overcharged, volatile gas is emitted from the plates, and electrolyte temperature rises. This temperature rise causes more rapid loss of water from the battery electrolyte. This water loss and temperature rise will shorten the battery life, If left...

Battery

Remove all necessary components to gain access to the battery terminals. Hydrometer testing is the best way to check battery condition. Use a hydrometer with numbered graduations from 1.100 to 1.300 rather than one with just color-coded bands. To use the hydrometer, squeeze the rubber ball, insert the tip into the cell and release the ball. Draw enough electrolyte to float the

High Beam Relay

If the relay does not click, check the connector for a loose connection check also for a blown fuse. If there is no problem, check for battery voltage between the blue and green wires of the 4P mini connector. If the battery voltage is measured, replace the high beam relay. If the battery voltage is not measured, there is an open circuit in the blue wire.

Output of Generator

Mount the generator on a conventional test stand so as to drive generator counterclockwise (looking at generator drive gear end). Connect positive lead from ammeter to the relay terminal. The other ammeter lead must be connected to a 6-volt storage battery positive post and the battery negative post grounded to the test stand (generator frame). This connects the generator to use the regulating field coil only, the same as operating the vehicle with the lights off. If the test stand has variable speed drive, operate the generator through full range of speeds from lowest to the highest. Run generator until it becomes quite warm.

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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