Table of Contents

Exploded View 15-4

Specifications 15-7

Special Tools 15-8

Precautions 15-9

Battery 15-9

Precautions 15-9

Electrolyte Level Inspection 15-10

Battery Condition 15-10

Battery Initial Charging 15-11

Battery Ordinary Charging 15-11

Battery Test Charging 15-12

Battery Case Removal 15-13

Battery Case Installation 15-14

Battery Vent Hose Routing 15-14

Charging System 15-14

Inside Alternator Cover Removal 15-15

Inside Alternator Cover

Installation Notes 15-15

Alternator Rotor Removal 15-15

Alternator Rotor Installation Notes 15-16

Regulator/Rectifier Output

Voltage Measurement 15-17

Regulator/Rectifier Output

Current Measurement •.. 15-17

Stator Coil Resistance Measurement 15-17

Stator Coil Insulation Test 15-18

Regulator/Rectifier Inspection 15-18

Ignition System 15-19

Ignition System Troubleshooting 15-20

Safety Instructions 15-21

Spark Plug Removal/Installation Note 15-21

Spark Plug Cleaning and Inspection 15-21

Spark Plug Gap 15-21

Ignition Coil Installation Notes 15-21

Ignition Coil Arcing

Distance Measurement 15-22

Ignition Coil Resistance Measurement 15-22

Ignition Timing Inspection (Dynamic). . . . 15-23

IC Ignitor Inspection 15-23

Outside Alternator Cover Removal 15-24

Outside Alternator Cover Installation 15-25

Pickup Coil Removal 15-25

Pickup Coil Installation Notes 15-25

Pickup Coil Inspection 15-26

Electric Starter System 15-26

Starter Motor Removal 15-26

Starter Motor Installation Notes 15-27

Starter Motor Disassembly 15-27

Starter Motor Assembly 15-28

Yoke Assembly Note 15-29

Electric Starter System

Inspection Caution 15-29

Starter Relay Inspection 15-29

Brush Inspection 15-30

Brush Spring Inspection 15-30

Commutator Cleaning and Inspection 15-30

Armature Inspection 15-31

Brush Plate Inspection 15-31

Brush and Lead Assembly Inspection 15-31

Torque Limiter Installation Note 15-31

Torque Limiter Inspection 15-32

Starter Clutch Removal 15-32

Starter Clutch Installation 15-32

Starter Clutch Disassembly 15-32

Starter Clutch Assembly Notes 15-32

Starter Clutch Inspection 15-32

Lighting System 15-33

Headlight Beam Horizontal Adjustment. . . 15-33

Headlight Beam Vertical Adjustment 15-33

Headlight Removal 15-33

Headlight Bulb Replacement Notes 15-34

Headlight Unit Installation Notes 15-34

Tail/Brake Light and License Plate

Light Bulb Replacement Notes 15-35

Lighting System Inspection Note 15-35

Headlight Reserve Lighting System

Inspection 15-37

Turn Signal Circuit 15-37

Turn Signal Light Bulb Replacement 15-37

Turn Signai Relay Inspection 15-39

Automatic Cancelling Distance

Sensor Inspection 15-39

Cooling Fan System 1540

Radiator Fan Removal 15-40

Fan System Circuit Inspection 15-40

Fan Motor Inspection 15-41

Fan Relay Inspection 15-41

Fan Switch Inspection 15-41

Meter and Gauges 1542

Meter Panel Remo val 15-42

Meter Panel Disassembly 15 -43

Tachometer Unit Disassembly 15-43

Tachometer Unit Assembly 15-43

Bulb Replacement Notes 15-44

Fuel Gauge Unit Removal Note 15-45

Fuel Gauge Unit Installation Note 15-45

Fuel Gauge Operation Inspection 15-45

Water Temperature Gauge

Operation Inspection 15-46

Switch and Sensors 15-46

Rear Brake Light Switch Inspection 15-46

Rear Brake Light Switch Adjustment 15-47

Rear Brake Light Switch Removal . 15-47

Switch Inspection 15-47

Fuel Level Sensor Installation 15-48

Fuel Level Sensor Inspection 15-48

Water Temperature Sensor

Removal Note 15-49

Water Temperature Sensor

Installation Note 15-49

Water Temperature Sensor Inspection 15-49

Junction Box 15-50

Fuse Remo va! 15-50

Fuse Installation Note . 15-51

Fuse Inspection 15-51

Junction Box Fuse Circuit Inspection 15-51 Fan, Starter Relay and

Headlight Relay Inspection 15-51

Diode Circuit Inspection 15-52

Electrical Wiring 15-52

Wiring Inspection 15-52

Wiring Diagram 15-53


O: Apply engine oil.

1. IC Ignitor:

The IC ignitor has mainly two functions. The first function is to supply current to the primary winding of the ignition coil. The second function is to determine the ignition timing with the power transistor in the ignitor.

2. Pickup Coil:

Every time either end of the timing plate on the alternator rotor passes under the pickup coil, a pulse is generated and sent to the IC ignitor.

Interlock Circuit:

If the side stand is down, the clutch engaged, and the transmission in gear, the ignition system will not work. If any of these conditions is not met, the ignition system works and the engine can be started and run. The motorcycle cannot be ridden with the side stand down.

1. Side Stand Switch

2. Rear Brake Light Switch

3. Turn Signal Relay

4. Reserve Lighting Unit

5. Turn Signal Control Unit

6. Fuse

7. Junction Box


Ignition Timing/Engine Speed Relationship



12 V 14 Ah

Specific gravity:

1.28 @20°C (68°F)

Charging System

Regulator/rectifier output voltage: Battery voltage to 14 - 15 V Night, @4,000 r/min (rpm) Stator coil resistance: 0.34 - 0.52 i2

00 20

1000 3000 5000 Engine Speed r/min (rpm)


Ignition System

Spark plug gap: 0.8 - 0.9 mm Plug cap resistance: 3.75 — 6.25 kO Ignition coil resistance

Primary winding: 1.8 - 2.2 £2 Secondary winding: 19 — 29 ki2 Ignition timing: 5° BTDC @1,100 r/min (rpm) -25° BTDC 3,500 r/min (rpm) Pickup coil resistance: 355 — 535 £2_

Starter System

Starter motor:

Carbon brush length:

Standard: 12.0-12.5 mm Service limit: 8.5 mm Commutator diameter:

Standard: 27.9 - 28.3 mm Service limit: 27.0 mm

Switches and Sensors

Front brake light switch: Rear brake light switch:

Non adjustable On after about 15 mm pedal travel Fuel level sensor resistance:

Full position 3 - 12 S2 Empty position 70 - 120 i2 Water temperature sensor resistance:

80°C (176°F) 42 — 62 100°C (212°F) 22 — 33 i2 Fan Switch resistance:

Special Tools

Rotor Puller: 57001-1099, or 57001-1216

Flywheel Holder: 57001-308


oThe flywheel holder (P/N 57001-1313) can be used instead of the flywheel holder (P/N 57001-308).


Male Connectors

There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below.

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.

oThe 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. 0T0 prevent damage to 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. oBecause of the large amount of current, never keep the starter switch pushed when the starter motor will not turn over, or the current may burn out the starter motor windings. 0D0 not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram, as the meter or gauge panel could be warped by excessive heat radiated from the bulb. °Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. oTroubles 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 must be repaired or replaced, or the new replacement will soon fail again.

oMake sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation. oMeasure coil and winding resistance when the part is cold (at room temperature).

oElectrical Connectors

Female Connectors

oColor Codes: BK BL BR CH DG G





Dark green



Light blue

Light green








Following a few simple rules will greatly extend the life of the battery.

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 supplemental charge, and never let a discharged battery stand without charging it. If a battery stands for any length of time, it slowly self-discharges. Once it is discharged, the plates sulphate (turn white), and the battery will no longer take a charge.

oKeep the battery well-charged during cold weather so that the electrolyte does not freeze and crack open the battery. The more discharged the battery becomes, the more easily it freezes.

oDON'T INSTALL THE BATTERY BACKWARDS. The negative side is grounded.


Electrolyte Level Inspection •Remove the battery.

•Visually check the electrolyte level in the battery.

A. Battery

B. Upper Level

C. Lower Level

*lf the level line of electrolyte in any cell is below the lower level line on the battery case, add distilled water only to that cell. •Install the battery.

A. Sulfation here B. Sediment here

Battery Condition

•Before charging, check battery condition by testing the specific gravity of the electrolyte in each cell. oDraw a little fluid from the cell with a hydrometer. oRead the level of the electrolyte on the floating scale. This is the specific gravity of the electrolyte.

•See the Battery Troubleshooting Guide in Battery Test Charging.

*lf the specific gravity is below 1.200, the battery needs to be charged.


oThe specific gravity of the electrolyte varies with changes in temperature, so the specific gravity reading must be corrected for the temperature of the electrolyte.

oCelsius: Add 0.007 points to reading for each 10°C above 20°C or subtract 0.007 points for each 10°C below 20° C.

oFahrenheit: Add 0.004 points to reading for each 10°F above 68°F or subtract 0.004 points for each 10°F below 68°F.

*lf the specific gravity of any of the celis is more than 0.050 away from any other reading, the battery will probably not accept a charge. It is generally best to replace a battery in this condition. *lf the specific gravity of all the cells is 1.280 or more, the battery is fully charged.

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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