ANUAL SERVICE M

BATTERY/CHARGING SYSTEM

COMPONENT LOCATION

'05 - '07 shown:

SYSTEM DIAGRAM

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.

• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.

- If electrolyte gets on your skin, flush with water.

- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.

• Electrolyte is poisonous.

- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.

• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space.

• For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.

• The battery sealing caps should not be removed. Attempting to remove the sealing caps from the cells may damage the battery.

• The maintenance free battery must be replaced when it reaches the end of its service life.

• The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same con­ditions contribute to shortening the life span of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years.

• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventu­ally die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly.

• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load.

• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent sulfation from occurring.

• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery life is lengthened when it is initially charged.

• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-5).

• For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery.

BATTERY TESTING

Refer to the instructions in the Operation Manual for the recommended battery tester. The recommended battery tester

puts a "load" on the battery so the actual battery condition of the load can be measured.

Recommended Battery Tester: Micro 404XL (U. S.A. only), BM-210 or equivalent

SPECIFICATIONS

TOOLS

TROUBLESHOOTING

BATTERY IS DAMAGED OR WEAK

1. BATTERY TEST

Remove The battery (page 17-6).

Check the battery condition using the recommended battery tester.

RECOMMENDED BATTERY TESTER:

Micro 404XL (U. S.A. only), BM-210 or equivalent

Is the battery in good condition7

NO - Faulty battery.

YES - GO TO STEP 2.

2. CURRENT LEAKAGE TEST

Install the battery (page 17-6).

Check the battery current leakage test (Leak test; page 17-7).

Is the current leakage below 0.1 mA?

YES - GO TO STEP 4.

NO - GO TO STEP 3.

3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTED Disconnect the regulator/rectifier connector and recheck the battery current leakage.

Is the current leakage below 0.1 mA7

YES - Faulty regulator/rectifier.

NO - Shorted wire harness.

4. ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil (page 17-8).

Check for continuity between Yellow terminal and Ground, White terminal and Ground. Is there continuity?

NO - Faulty charging coil.

YES - GO TO STEP 5.

5. CHARGING VOLTAGE INSPECTION

Measure and record the battery voltage using a digital multimeter (page 17-6).

Start the engine.

Measure the charging voltage (page 17-7).

Compare the measurements to the results of the following calculation.

STANDARD:

Measured BV < Measured CV < 15.5 V

• BV = Battery Voltage

• CV = Charging Voltage

Is the measured charging voltage within the standard voltage?

YES - Faulty battery.

NO - GO TO STEP 6.

6. REGULATOR/RECTIFIER SYSTEM INSPECTION

Check the voltage and resistance at the regulator/rectifier connector (page 17-8).

Are the result of checked voltage and resistance correct?

YES - Faulty regulator/rectifier.

NO - • Open circuit in related wire

• Loose or poor contacts of related terminal

• Shorted wire harness

BATTERY

REMOVAL/INSTALLATION

Remove the seat (page 3-3).

Remove the battery holder.

Disconnect the negative (-) cable and then the posi­tive (+) cable, and remove the battery.

Installation is in the reverse order of removal.

After installing the battery, coat the terminals with clean dielectric grease.

VOLTAGE INSPECTION

Measure the battery voltage using a digital multimeter.

VOLTAGE:

Fully charged: 13.0-13.2 V

Under charged: Below 12.4 V

TOOL:

Digital multimeter Commercially available in

U. S.A.

BATTERY TESTING

Remove the battery (page 17-6).

Refer to the instructions that are appropriate to the battery testing equipment available to you.

TOOL:

Battery tester Micro 404XL (U. S.A. only),

BM-210 or equivalent

BATTERY CHARGING (U. S.A. only)

Remove the battery (page 17-6).

Refer to the instructions that are appropriate to the battery charging equipment available to you.

TOOL:

Christie battery charger MC1012/2T (U. S.A. only)