ELECTRICAL SYSTEM
CONTENTS
LOCATION OF ELECTRICAL COMPONENTS 6- 1
IGNITION SYSTEM 6- 3
CHARGING SYSTEM 6- 7
STARTER SYSTEM AND
SIDE STAND IGNITION INTERLOCK SYSTEM 6- 11
SWITCHES 6- 15
LAMP 6- 16
BATTERY 6- 18
6
6-1 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
Battery Cooling fan motor Front brake lamp switch
Turn signal relay Cooling fan thermo-switch
Head lamp relay
Side stand relay
Cooling fan motor relay
Rear brake lamp switch Side stand switch Starter motor
ELECTRICAL SYSTEM 6-2
Ignition coil (NO.1 & NO.2) Engine coolant temperature sensor Regulator / Rectifier
Thermostat
Magneto Gear position switch Fuse
Igniter
Pulse control unit
6-3 ELECTRICAL SYSTEM
IGNITION SYSTEM
is started as the battery discharged ignition system without a contact point. The battery ignition system
is composed a rotor with four rotor tip, the igniter, the ignition coil and battery. This system ignites after get signal from
ignition timing of pick-up with the electric energy of this battery and occur the 1st electric current. Therefore, a high volt-
age current is induced in the secondary winding of the ignition coil and results in strong spark between spark plug gap.
Magneto Igniter
KILL S/W IG. S/W
Rr. IGNITION COIL
Y
Ft. IGNITION COIL
G FUSE
IGNITER
Y REG
REC
L BATTERY
Y
12V 12Ah
Ignition coil & Spark plug
ELECTRICAL SYSTEM 6-4
INSPECTION
MAGNETO
Using the pocket tester, measure the resis-
t a n c e between the lead wires in the following
table.
Pick-up coil G-L 90 110
Charging coil Y-Y 0.3 0.8
Pocket Tester : 09900-25002
CAUTION
When mounting the stator on the magneto cover,
apply a small quantity of THREAD LOCK 1324
to the threaded parts of screws.
THREAD LOCK 1324
WIRE COLOR
L : Blue
G : Green
Y : Yellow
BY : Black with Yellow tracer
OB : Orange with Black tracer
Br : Brown
BW : Black with White tracer
WL : White with Blue tracer
YG : Yellow with Green tracer
SPARK PLUG
Clean the plug with a wire brush and pin. Use the pin
to remove carbon, taking care not to damage the
porcelain.
Check the gap with a thickness gauge.
Thickness gauge : 09900-20806
0.7 0.8 mm
Spark plug gap
(0.028 0.032 in)
0.7 0.8 mm
(0.028 0.032 in)
6-5 ELECTRICAL SYSTEM
IGNITION COIL
Pull out the spark plug.
Place it on the cylinder head after installing it at the
plug cap to obtain ground.
Push the electric starter switch to rotate the starter
motor, to have the test of sparking performance.
If spark doesn t emit or the spark bring out the
orange color, replace the ignition coil.
CAUTION
The ignition coil is marked the F for front, and
the R for rear. Front cylinder ignition coil Rear cylinder ignition coil
If otherwise, it may occure severe damage to the
engine.
IGNITION COIL (Checking with Pocket Tester)
A pocket tester or an ohm meter may be
used, instead of the electro tester. In either case,
the ignition coil is to be checked for continuity in
both primary and secondary windings. Exact ohmic B/R
readings are not necessary, but, if the windings
are in sound condition, their continuity will be
noted with approximate ohmic values.
Ground
Ignition coil resistance Plug cap
Primary 3.5 5.5 Tester knob indication 1 range
Secondary 20 31 Tester knob indication 1 range
Check to attached plug cap
Pocket tester : 09900-25002
ELECTRICAL SYSTEM 6-6
IGNITER
Using the pocket tester(R 1 range), measure the
resistance between the terminal in the following table.
CAUTION
Numberical value may differ a little according
to the tester.
Please remind that there may be a defect
which can not be identified even though the
measurement by using the tester indicates a
low voltage.
The range of measurement adjust a [ X 1 ]
unit.
Pocket Tester : 09900-25002
6-7 ELECTRICAL SYSTEM
CHARGING SYSTEM
The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator /
rectifier unit and battery. The AC current generated from the AC generator is converted by the rectifier
and is turned into the DC current, then it charges the battery.
Regulator / Rectifier
IG. switch
A. C generator
Battery
IC
LOAD
FUNCTION OF REGULATOR
While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage
of the regulator, the regulator does not function, incidentally the generated current charges the battery directly.
Regulator / Rectifier
IG. switch
A. C generator
Battery
IC
LOAD
ELECTRICAL SYSTEM 6-8
When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and
the voltage between points and of the regulator according becomes high, and when it reaches the
adjusted voltage of the control unit, consequently the control unit becomes ON condition. On the ON con-
dition of the control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become ON
condition. Then the SCR becomes conductive to the direction from point to point . Namely at the state of
this, the current generated from the AC generator gets through SCR without charging the battery and returns to
the AC generator again. At the end of this state, since the AC current generated from the AC generator flows into
the point , reverse current tends to flow to SCR, then the circuit of SCR turns to OFF mode and begins to
charge the battery again. Thus these repetitions maintain charging constant voltage to the battry and protect it
from overcharging.
Regulator / Rectifier
IG. switch
A. C generator
Battery
IC
LOAD
6-9 ELECTRICAL SYSTEM
INSPECTION
CHARGING OUTPUT CHECK
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the DC volt-
age between the battery terminal and .
If the tester reads under 13.5V or over 15.0 V, check
the magneto no-load performance and regulator /
rectifier.
CAUTION
When making this test, be sure that the battery is
full-charged condition.
IG. switch
Pocket tester : 09900-25002
Standard charge 13.5 15.0V (at 5,000 rpm) Regulator
Rectifier
Battery DCV
MAGNETO NO-LOAD PERFORMANCE
Disconnect the three lead wires from the magneto
terminal.
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the AC volt-
age between the three lead wires.
If the tester reads under 70 V the magneto is faulty.
Standard NO-load perfor-
Over 70 V (at 5,000 rpm)
mance of magneto
ELECTRICAL SYSTEM 6-10
REGULATOR / RECTIFIER
Disconnect the coupler.
Using the pocket tester ( 1 range), measure the
resistance between the terminals in the following
table.
If the resistance checked is incorrect, replace the regu
lator / rectifier.
Pocket tester : 09900-25002
Unit :
Tester probe
Tester probe
3 4 3 4 1 2 1 2
3 4 3 4 1 2 1 2
3 4 3 4 1 2 1 2
1 2 1 2 1 2 32
1 2 1 2 1 2 32
PULSE CONTROL UNIT
Using the pocket tester (R 1 range), measure
the resistance between the terminals in the following
table.
Pocket tester : 09900-25002
Unit :
6-11 ELECTRICAL SYSTEM
STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM
STARTER SYSTEM DESCRIPTION
The starter system consists of the following components : the starter motor, starter relay, clutch lever position
switch, igniter, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery.
Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact
points to close, thus completing the circuit from the starter motor to the battery.
START
SWITCH IG. SWITCH
FUSE
NEUTRAL
INDICATOR
BATTERY
CLUTCH LEVER NEUTRAL
SWITCH SWITCH
SIDE STAND
RELAY
SIDE STAND
START RELAY
START SWITCH
MOTOR
SIDE STAND / IGNITION INTERLOCK SYSTEM DESCRIPTION
This side stand / ignition interlock system prevents the motorcycle from being started with side stand down.
The system is operated by an electric circuit provided between the battery and ignition coil.
The circuit consists of the igniter, neutral indicator light and switches.
The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and
whether the side stand is either up or down.
The gear position and side stand switches work together in this system.
The ignition coil work only in two situations as follows.
SIDE STAND
RELAY
IGNITION SWITCH
BATTERY IGNITION COIL
NEUTRAL
INDICATOR LIGHT
DIODE
SIDE STAND SW.
NEUTRAL SW.
ELECTRICAL SYSTEM 6-12
TRANSMISSION : Neutral - ON
Side stand - Down
Clutch lever - Pull
SIDE STAND RELAY
IGNITION SWITCH ON
ON
BATTERY IGNITION COIL
NEUTRAL
INDICATOR LIGHT
DIODE
SIDE STAND SW.
NEUTRAL SIDE STAND
SW. ON DOWN POSITION
TRANSMISSION : Neutral - OFF
Side stand - Up
Clutch lever - Pull
SIDE STAND RELAY
ON
IGNITION SW.
ON
BATTERY IGNITION COIL
NEUTRAL
INDICATOR LIGHT
DIODE
NEUTRAL SW. SIDE STAND SW.
OFF UP-RIGHT POSITION
is equipped with the side stand ignition interlock system.
If the transmission is in neutral or side stand up, you can only start the engine with pulling in the clutch
lever.
No Neutral switch Clutch lever Side stand Engine Start
1 Possible
NOTE
2 Possible
On or Up.
3 Impossible
Off or Down
4 Impossible
5 Impossible
6-13 ELECTRICAL SYSTEM
STARTER MOTOR REMOVAL AND
DISASSEMBLY
Disconnect the starter motor lead wire .
With loosening the bolt , remove the starter motor.
Disassemble the starter motor.
STARTER MOTOR INSPECTION
CARBON BRUSH
Inspect the brushes for abnormal wear, crack
or smoothness in the brush holder.
If the brush has failed, replace the brush sub assy.
COMMUTATOR
Inspect the commutator for discoloration, abnormal
wear or undercut .
If the commutator is abnomally worn, replace the Segment
armature.
When surface is discolored, polish it with #400
sand paper and clean it with dry cloth.
ARMATURE COIL INSPECTION
Check for continuity between each segment.
Check for continuity between each segment and
the armature shaft.
If there is no continuity between the segments or
there is continuity between the segment and shaft,
replace the starter motor with a new one.
Pocket tester : 09900-25002
ELECTRICAL SYSTEM 6-14
STARTER MOTOR REASSEMBLY
Reassemble the starter motor. Pay attention to the following points :
Reassembly the starter motor as shown in the illustration.
Align the mark on the housing with the line
on the housing end.
Apply SUPER GREASE A to the O-ring
and remount the starter motor.
SUPER GREASE A
6-15 ELECTRICAL SYSTEM
SWITCHES
Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch
assemblies with new ones.
Pocket tester : 09900-25002
IGNITION SWITCH ENGINE STOP SWITCH
R O BW BR O OB
ON
OFF
LOCK
HAZARD SWITCH STARTER SWITCH
Sb Gr OB YR
ON ON
OFF OFF
DIMMER SWITCH HORN SWITCH
YW Y W BBr BW
HI ON
LO OFF
TURN SIGNAL SWITCH FRONT/REAR BRAKE LAMP SWITCH
Lg Sb B O WB
L ON
PUSH OFF
R
PASS SWITCH
O Y
ON
OFF
ELECTRICAL SYSTEM 6-16
LAMP
HEADLAMP
TURN SIGNAL LAMP
TAIL / BRAKE LAMP
6-17 ELECTRICAL SYSTEM
COMBINATION METER
Remove the combination meter.
Disassemble the combination meter as shown in
the illustration.
INSPECTION
Using the pocket tester, check the continuity
between lead wires in the following illustration.
If the continuity measured incorrect, replace the
respective part.
Pocket tester : 09900-25002
CAUTION
When making this test, it is not necessary to
remove the combination meter.
TACHO
TEMP
METER
GAUGE
WB(1/2 Point)
YB(E Point)
ELECTRICAL SYSTEM 6-18
BATTERY
CAUTION OF BATTERY TREATMENT
The battery needs attention generally as it occur flammability gas.
If you don t follow the instruction in the below, there may be a explosion and severe accident.
Therefore, please pay attention to the following points.
Prohibit positively battery from contacting to short, spark or firearms.
The recharge of battery should be done in the wide place where the wind is well ventilated.
Please don t recharge it at the sight of wind-proof.
CAUTION OF BATTERY ELECTROLYTE TREATMENT
Pay attention for the battery electrolyte not to stains the chassis or the humanbody.
If stains the chassis or the humanbody, at once wash a vast quantity of water.
When it be stained, clothes should come into being a hole or painting should take off.
Consult a doctor.
When the battery electrolyte was dropped to the surface of land, wash a vast quantity of water.
Neutralize by hydroxide, bicarbonate of soda and so on.
CAUTION OF MAINTENANCE FREE
BATTERY TREATMENT
Do not remove the aluminum tape to seal the bat-
tery electrolyte filler hole untill use as battery of com-
pletely seal type.
Do not use it except the battery electrolyte.
When pour into the battery electrolyte, necessarily
use the electrolyte of the specified capacity.
Do not open the sealing cap after recharging the
battery eletrolyte.
Filling electrolyte.
Put the battery on even land and remove the alu-
minum tape sealing.
Remove the cap at the electrolyte container.
Aluminum tape
CAUTION
Do not remove the seal of the electrolyte Filler holes
container, not prick with sharp thing.
6-19 ELECTRICAL SYSTEM
Cap Seal
Pouring of battery electrolyte
When insert the nozzles of the electrolyte container into
the battery s electrolyte filler holes, holding the container
firmly so that it does not fall.
Take precaution not to allow any fluid to spill.
CAUTION
The pouring of electrolyte may not be done if
the electrolyte container is pushed slopely.
Confirmation of pour
Make sure that air bubbles are coming up each
electrolyte container, and keep this position for more
than about 20 minutes.
CAUTION
If no air bubbles are coming up from a filler Air bubble
port, tap the bottom of the two or three times.
ELECTRICAL SYSTEM 6-20
Separation of electrolyte container
After confirming that you entered the electrolyte into
battery completely, remove the electrolyte containers
from the battery.
CAUTION
Draw the empty receptacle out slowly because
there may be a chance which remaining elec-
trolyte vaporize.
Insert the caps
Insert the cap into the filler holes, pressing it firmly so
that the top of the caps do not protrude above the upper
surface of the battery s top cover.
Insert the caps firmly
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.
RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If
How to charge
the voltage reading is less than the 12.0V (DC),
recharge the battery with a battery charger. Standard 1.2 A 5~10 hours
Fast 6A 30 minutes
CAUTION
When recharging the battery, remove the battery
from the motorcycle.
NOTE
Do not remove the caps on the battery top while
recharging.
CAUTION
Be careful not to permit the charging current to
exceed 6A at any time.
After recharging, wait for more than 30 minutes and
check the battery voltage with a pocket tester.
If the battery voltage is less than the 12.5V, recharge
the battery again.
If battery voltage is still less than 12.5V, after
recharging, replace the battery with a new one.
When the motorcycle is not used for a long period,
check the battery every 1 month to prevent the bat-
tery discharge.
