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9-6 ELECTRICAL SYSTEM

LOCATION OF ELECTRICAL COMPONENTS

E

L

P

M

A

S

1 Fuel pump relay ( 5-7)

9 Fuel pump ( 5-8)

2 IAT sensor ( 4-53)

0 Regulator/Rectifier

3 Cooling fan relay ( 7-7)

A Oil pressure switch

4 PAIR control solenoid valve ( 11-7)

B Generator

5 CMP sensor ( 4-33)

C Speed sensor

6 Ignition coil (No.1, 2, 3, 4)

D GP switch

7 Horn

E Side-stand switch

8 Fuel level gauge

F TO sensor ( 4-63)

ELECTRICAL SYSTEM 9-7

E

L

P

M

A

S

1 Battery

0 STP sensor ( 4-70)

2 AP sensor ( 4-57)

A TP sensor ( 4-44)

3 Mode selection switch coupler ( 4-18)

B IAP sensor ( 4-38)

4 Fuse Box

C Starter relay/Main fuse

5 ECM (Engine Control Module)

D Turn signal/Side-stand relay

6 Secondary fuel injector ( 4-80)

E EXCVA ( 6-4)

7 Primary fuel injector ( 4-77)

F CKP sensor ( 4-35)

8 ECT sensor ( 4-49)

G HO2 sensor (E-02, 19) ( 4-87)

9 STV actuator ( 4-67)

H Cooling fan ( 7-6)

9-8 ELECTRICAL SYSTEM

CHARGING SYSTEM

Regulator/Rectifier

IG. switch

Generator

IC

 

Battery

Load

SCR

 

 

 

 

 

 

 

TROUBLESHOOTING

 

 

P

E

 

 

 

Battery runs down quickly

 

 

 

Step 1

 

 

 

 

 

 

 

L

1) Check accessories which use excessive amounts of electricity.

 

Are accessories being installed?

 

M

 

 

 

 

 

 

 

 

 

 

YES

 

A

 

 

Remove accessories.

 

 

 

NO

Go to tep 2.

 

 

 

 

Step 2

S

 

 

 

1) Check the battery for current leaks. ( 9-9)

 

 

Is the battery for current leaks OK?

 

 

 

 

 

 

 

 

 

YES

Go to Step 3.

 

 

 

 

 

 

 

 

NO

• Short circuit of wire harness

 

 

• Faulty electrical equipment

 

 

 

 

 

 

 

 

 

 

 

Step 3

1)Measure the regulated voltage between the battery terminals. ( 9-10) Is the regulated voltage OK?

YES

Faulty battery

Abnormal driving condition

 

 

 

NO

Go to Step 4.

Step 4

1)Measure the resistance of the generator coil. ( 9-10) Is the resistance of generator coil OK?

YES

Go to Step 5.

NO

Faulty generator coil

Disconnected lead wires

 

 

 

 

Go to Step 7.
Faulty regulator/rectifier

ELECTRICAL SYSTEM 9-9

Step 5

1)Measure the generator no-load performance. ( 9-11) Is the generator no-load performance OK?

YES

Go to Step 6.

 

 

NO

Faulty generator

 

 

Step 6

1)Inspect the regulator/rectifier. ( 9-11) Is the regulator/rectifier OK?

YES

NO

Step 7

1)Inspect wirings. Is the wirings OK?

YES

Faulty battery

 

 

 

 

 

 

 

 

 

 

 

 

 

NO

• Short circuit of wire harness

 

 

 

 

 

• Poor contact of couplers

 

 

 

 

 

 

 

 

 

 

 

 

 

Battery overcharges

 

 

 

E

 

• Faulty regulator/rectifier

 

 

 

 

 

L

 

• Faulty battery

 

 

 

 

P

 

 

 

• Poor contact of generator lead wire coupler

 

 

 

 

 

 

 

 

INSPECTION

M

 

 

 

 

 

BATTERY CURRENT LEAKAGE

 

 

 

 

 

 

• Remove the front seat. ( A8-7)

 

 

 

 

 

 

 

S

 

 

 

 

 

 

• Turn the ignition switch to the OFF position.

 

 

 

 

 

 

• Disconnect the battery - lead wire.

 

 

 

 

 

 

• Measure the current between - battery terminal and the -

 

 

 

battery lead wire using the multi-circuit tester. If the reading

 

 

 

exceeds the specified value, leakage is evident.

 

 

 

 

 

09900-25008: Multi-circuit tester set

 

 

 

 

 

 

Battery current (leak): Under 3 mA

 

 

 

 

 

 

 

 

 

 

 

A

Tester knob indication: Current ( , 20 mA)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

*In case of a large current leak, turn the tester to high range first to avoid tester damage.

*Do not turn the ignition switch to the “ON” position when measuring current.

9-10 ELECTRICAL SYSTEM

REGULATED VOLTAGE

• Remove the front seat. ( 8-7)

 

 

 

 

 

 

 

 

• Start the engine and keep it running at 5 000 r/min with the

 

 

 

 

 

 

 

 

dimmer switch turned HI position.

 

 

 

 

 

 

 

 

• Measure the DC voltage between the + and - battery termi-

 

 

 

 

 

 

 

 

nals using the multi-circuit tester. If the voltage is not within

 

 

 

 

 

 

 

 

the specified value, inspect the generator and regulator/recti-

 

 

 

 

 

 

 

 

fier. ( 9-10 and -11)

 

 

 

 

 

 

 

 

NOTE:

 

 

 

 

 

 

 

 

When making this test, be sure that the battery is in fully-charged

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

condition.

 

 

 

Battery

09900-25008: Multi-circuit tester set

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tester knob indication: Voltage ( )

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Regulated voltage (Charging output):

 

 

 

 

DCV

 

 

 

 

 

 

 

 

 

14.0 – 15.5 V at 5 000 r/min

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GENERATOR COIL RESISTANCE

 

L

 

E

• Lift and support the fuel tank. ( 5-3)

P

 

 

• Disconnect the generator coupler.

M

 

 

 

• Measure the resistance between the three lead wires.

 

If the resistance is out of specified value, replace the stator

 

A

 

with a new one. Also, check that the generator core is insulated properly.

09900-25008: Multi-circuitStester set

Tester knob indication: Resistance ()

Generator coil resistance: 0.2 – 1.0 (Yellow – Yellow)

(Yellow – Ground)

NOTE:

When making above test, it is not necessary to remove the generator.

Y

Y

Y

1.4 V and

ELECTRICAL SYSTEM 9-11

GENERATOR NO-LOAD PERFORMANCE

 

 

 

 

 

 

 

 

Lift and support the fuel tank. ( 5-3)

 

 

 

 

 

 

 

 

• Disconnect the generator coupler.

 

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

• Start the engine and keep it running at 5 000 r/min.

 

 

 

 

 

 

 

 

 

 

 

 

 

• Using the multi-circuit tester, measure the voltage between

 

 

Y

 

 

 

three lead wires.

 

 

 

 

 

Y

 

 

 

If the tester reads under the specified value, replace the gen-

 

 

 

 

 

 

 

 

 

 

 

erator with a new one.

 

 

 

 

 

 

 

 

09900-25008: Multi-circuit tester set

 

 

 

 

 

 

 

 

Tester knob indication: Voltage (~)

 

 

 

 

 

 

 

 

Generator no-load performance:

 

 

 

 

 

 

 

 

 

 

65 V and more at 5 000 r/min (When engine is cold)

 

 

 

 

 

REGULATOR/RECTIFIER

 

 

 

 

 

 

 

 

Lift and support the fuel tank. ( 5-3)

 

 

 

 

 

 

 

 

• Remove the air cleaner box. ( 5-14)

 

 

 

 

 

 

 

 

Disconnect the regulator/rectifier couplers.

 

 

 

E

 

• Measure the voltage between the lead wires using the multi

 

 

circuit tester as indicated in the table below. If the voltage is

 

 

not within the specified value, replace the regulator/rectifier

 

 

with a new one.

 

 

L

 

 

 

 

 

 

 

 

 

 

 

 

09900-25008: Multi-circuit tester set

P

 

 

 

 

 

 

 

 

 

 

Tester knob indication: Diode testM( )

 

 

 

 

B/R1

B/W1

 

 

 

 

B/R2

B/W2

 

 

 

 

 

A

 

Unit: V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+ Probe of tester to:

 

 

 

 

 

 

 

B2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to:

 

 

 

S

 

 

 

 

 

 

 

 

 

B1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tester

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

- Probe of

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

more (tester’s battery voltage)

NOTE:

If the tester reads 1.4 V and below when the tester probes are not connected, replace its battery.

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