310
CHAPTER EIGHT
nals to prevent corrosion and deterioration of the
terminals.
9
19. Install the seat.
Inspection and Testing
The battery electrolyte level cannot be serviced.
Never attempt to remove the sealing bar cap (B,
Figure 8) from the top of the battery. This bar cap
was removed for the initial filling of electrolyte
prior to delivery of the motorcycle, or the installa-
tion of a new battery, and is not to be removed there-
after. The battery does not require periodic
6. Check the battery cable ends (C, Figure 10) for
electrolyte inspection or water refilling. Refer to the
corrosion and damage. If corrosion is minor, clean
label (Figure 9) on top of the battery.
the battery cable ends with a stiff wire brush. Re-
Even though the battery is a sealed type, protect
place worn or damaged cables.
eyes, skin and clothing; electrolyte, which is very
7. Connect a digital voltmeter between the battery
corrosive, may have spilled out and can cause se-
negative and positive leads. Note the following:
vere chemical skin burns and permanent injury. The
a. If the battery voltage is 12.6 volts (at 20° C
battery case may be cracked and leaking electrolyte.
[68° F]), or greater, the battery is fully
If any electrolyte is spilled or splashed on clothing
charged.
or skin, immediately neutralize with a solution of
b. If the battery voltage is 12.0 to 12.5 volts (at
baking soda and water, then flush with an abun-
20° C [68° F]), or lower, the battery is under-
dance of clean water.
charged and requires charging.
8. If the battery is undercharged, recharge it as de-
WARNING
scribed in this chapter. Then test the charging sys-
Electrolyte splashed into the eyes is
tem as described in Chapter Two.
extremely harmful. Always wear
safety glasses while working with a
9. Inspect the battery case for contamination or
battery. If electrolyte gets into the
damage. Clean with a solution of baking soda and
eyes, call a physician immediately
water.
and force the eyes open and flood
them with cool, clean water for ap-
proximately 15 minutes.
Charging
1. Remove the battery as described in this chapter.
Refer to Battery Initialization in this chapter if
Do not clean the battery while it is mounted in the
the battery is new.
frame.
If recharging is required on a maintenance-free
2. Set the battery on a stack of newspapers or shop
battery, a digital voltmeter and a charger with an ad-
cloths to protect the surface of the workbench.
justable amperage output are required. If this equip-
3. Check the entire battery case (A, Figure 10) for
ment is not available, it is recommended that battery
cracks or other damage. If the battery case is
charging be entrusted to a shop with the proper
warped, discolored or has a raised top, the battery
equipment. Excessive voltage and amperage from
has been overcharged and overheated.
an unregulated charger can damage the battery and
4. Check the battery terminal bolts, spacers and
shorten service life.
nuts (B, Figure 10) for corrosion or damage. Clean
The battery should only self-discharge approxi-
parts thoroughly with a solution of baking soda and
mately one percent each day. If a battery not in use,
water. Replace corroded or damaged parts.
with no loads connected, loses its charge within a
5. If corroded, clean the top of the battery with a
week after charging, the battery is defective.
stiff bristle brush using the baking soda and water
If the motorcycle is not used for long periods of
solution.
time, an automatic battery charger with variable
ELECTRICAL SYSTEM
311
CAUTION
10
If the battery emits an excessive
amount of gas during the charging cy-
cle, decrease the charge rate. If the
battery becomes hotter than 110° F
(43° C) during the charging cycle,
turn the charger to the OFF position
and allow the battery to cool. After
cooling down, continue with a re-
duced charging rate and continue to
monitor the battery temperature.
7. Turn the charger to the ON position.
8. After the battery has been charged for the
voltage and amperage outputs is recommended for
pre-determined time, turn the charger to the OFF
optimum battery service life.
position, disconnect the leads and measure the bat-
WARNING
tery voltage. Refer to the following:
During charging, highly explosive hy-
a. If the battery voltage is 12.6 volts (at 20° C
drogen gas is released from the bat-
[68° F]), or greater, the battery is fully
tery. The battery should be charged
charged
only in a well-ventilated area away
8
from open flames
(including pilot
b. If the battery voltage is 12.5 volts (at 20° C
lights on some gas home appliances).
[68° F]), or lower, the battery is undercharged
Do not allow any smoking in the area.
and requires additional charging time.
Never check the charge of the battery
9. If the battery remains stable for one hour, the
by arcing across the terminals; the re-
battery is charged.
sulting spark can ignite the hydrogen
gas.
10. Install the battery into the motorcycle as de-
scribed in this chapter.
CAUTION
Always disconnect the battery cables
from the battery. If the cables are left
Battery Initialization
connected during the charging proce-
dure, the charger may destroy the di-
A new battery must be fully charged to a specific
odes in the voltage regulator/rectifier.
gravity of 1.260-1.280 before installation. To bring
the battery to a full charge, give it an initial charge.
1. Remove the battery from the motorcycle as de-
Using a new battery without an initial charge will
scribed in this chapter.
cause permanent battery damage. That is, the bat-
2. Set the battery on a stack of newspapers or shop
tery will never be able to hold more than an 80%
cloths to protect the surface of the workbench.
charge. Charging a new battery after it has been
3. Make sure the battery charger is turned to the
used will not bring its charge to 100%. When pur-
OFF position, prior to attaching the charger leads to
chasing a new battery, verify its charge status.
the battery.
4. Connect the positive charger lead to the positive
NOTE
(+) battery terminal and the negative charger lead to
Recycle the old battery. When a new
the negative (-) battery terminal.
battery is purchased, turn in the old
one for recycling. Most motorcycle
5. Set the charger at 12 volts. If the output of the
dealerships will accept the old battery
charger is variable, select the low setting.
in trade when purchasing a new one.
6. The charging time depends on the discharged
Never place an old battery in the
condition of the battery. Refer to Table 3 for the
household trash since it is illegal, in
suggested charging time. Normally, a battery
most states, to place any acid or lead
should be charged at 1/10th its given capacity.
(heavy metal) contents in landfills.
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312
CHAPTER EIGHT
Load Testing
11
LOAD TEST
A load test checks the battery’s performance un-
der full current load and is the best indication of bat-
tery condition.
A battery load tester is required for this proce-
+
dure. When using a load tester, follow the manufac-
Load
Battery
turer’s instructions. Figure 11 shows a typical load
tester
tester and battery arrangement.
-
1. Remove the battery from the motorcycle as de-
scribed in this chapter.
NOTE
If the battery required charging, let
the battery stand for at least one hour
CHARGING SYSTEM
prior to performing this test.
An electrical diagram of the charging system is
2. The battery must be fully charged before begin-
shown in Figure 12 for 1999-2001 models. Refer to
ning this test. If necessary, charge the battery if nec-
the wiring diagrams at the end of the manual for
essary as described in this section.
2002-on models. The charging system consists of the
battery, alternator and voltage regulator/rectifier
WARNING
(Figure 13 and Figure 14). Alternating current gen-
The battery load tester must be turned
erated by the alternator is rectified to direct current.
to the OFF position prior to connect-
The voltage regulator maintains a constant voltage to
ing or disconnecting the test cables to
the battery. Otherwise, a spark could
the battery and additional electrical loads, such as the
cause the battery to explode.
lights and ignition system, at a constant voltage re-
gardless of variations in engine speed and load.
CAUTION
A malfunction in the charging system generally
To prevent battery damage during
causes the battery to remain undercharged. To pre-
load testing, observe these two re-
vent damage to the alternator and the regulator/rec-
quirements: Do not load test a dis-
tifier when testing and repairing the charging
charged battery and do not load test
system, note the following precautions:
the battery for more than 20 seconds.
1. Disarm the optional TSSM security system prior
Performing a load test on a dis-
to disconnecting the battery or the siren will sound.
charged battery can result in perma-
nent battery damage.
2. Always disconnect the negative battery cable, as
described in this chapter, before removing a compo-
3.
Load test the battery as follows:
nent from the charging system.
a. Connect the load tester cables to the battery
3. When it is necessary to charge the battery, re-
following its manufacturer’s instructions.
move the battery from the motorcycle and recharge
b. Load the battery at 50% of the cold cranking
it as described in this chapter.
amperage (CCA), or 135 amperes.
4. Inspect the battery case. Look for bulges or cracks
c. After 15 seconds, the voltage reading (with
in the case, leaking electrolyte or corrosion build-up.
the load still applied) must be 9.6 volts or
5. Check the charging system wiring for signs of
higher at 70° F (21° C). Now quickly remove
chafing, deterioration or other damage.
the load and turn the tester OFF.
6. Check the wiring for corroded or loose connec-
4.
If the voltage reading is 9.6 volts or higher, the
tions. Clean, tighten or reconnect as required.
battery output capacity is good. If the reading is be-
low 9.6 volts, the battery is defective.
Battery Drain
5. With the tester in the OFF position, disconnect
the cables from the battery.
Perform this test prior to performing the output
6. Install the battery as described in this chapter.
test.
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ELECTRICAL SYSTEM
313
12
CHARGING SYSTEM (1999-2001 MODELS)
Stator
Circuit
breaker
Diagram Key
30 A
Voltage
regulator
Connectors
Ground
Frame ground
Connection
No connection
8
-
+
Starter
Color Code
B Black
Battery
*Refer to the wiring diagrams at the end of this manual for 2002-on models
13
CHARGING SYSTEM COMPONENTS (FXDP)
1. Stator coil assembly
2. Allen bolt
3. Rotor
4. Washer
5. Cable seal
6. Terminal socket
7. Socket housing
8. Primary lock
9. Rubber boot
10. Secondary lock
11. Connector
12. Terminal pin
13. Heat sink tubing
14. Bolt
15. Voltage regulator
16. Nut
17. Mounting bracket
18. Washer
19. Lockwasher
20. Allen bolt
-------------------------------------------------------------------------------------------------------------------------------------------------------------
314
CHAPTER EIGHT
14
CHARGING SYSTEM COMPONENTS
(ALL MODELS EXCEPT FXDP)
1. Stator coil assembly
2. Allen bolt
3. Inner washer
4. Rotor
5. Outer washer
6. Cable seal
7. Terminal socket
To main
8. Socket housing
circuit
9. Primary lock
breaker
10. Rubber boot
(silver stud)
11. Secondary lock
12. Connector
13. Terminal socket
14. Bolt
15. Terminal pin
16. Voltage regulator
17. Heat sink tubing
18. Terminal pin
19. Heat sink tubing
20. Terminal pin
21. Bolt
22. Heat sink tubing
1. Turn the ignition switch OFF.
2. Remove the seat.
15
Ammeter
NOTE
Always disarm the optional TSSM se-
curity system prior to disconnecting
the battery or the siren will sound.
3. Disconnect the battery negative lead as de-
scribed in this chapter.
4. Switch the ammeter from its highest to lowest
amperage scale while reading the meter scale.
CAUTION
Battery
Before connecting the ammeter into
ground
the circuit in Step 4, set the meter to its
cable
highest amperage scale. This will pre-
vent a possible large current flow
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
315
b. Short circuit in the system.
16
c. Loose, dirty or faulty electrical system con-
nectors in the charging system wiring har-
ness.
7. Disconnect the ammeter test leads and reconnect
the battery negative lead.
Testing
A malfunction in the charging system generally
causes the battery to remain undercharged. Perform
the following visual inspection to determine the
cause of the problem. If the visual inspection proves
satisfactory, test the charging system as described
17
under Charging System in Chapter Two.
1. Make sure the battery cables (Figure 16) are
connected properly. If polarity is reversed, check
for a damaged rectifier.
2. Inspect the terminals for loose or corroded con-
8
nections. Tighten or clean as required.
3. Inspect the battery case. Look for bulges or
cracks in the case, leaking electrolyte or corrosion
buildup.
4. Carefully check all connections at the alternator
to make sure they are clean and tight.
5. Check the circuit wiring for corroded or loose
18
connections. Clean, tighten or connect as re-
quired.
ALTERNATOR
Rotor Removal/Installation
NOTE
Always disarm the optional TSSM se-
curity system prior to disconnecting
the battery or the siren will sound.
1. Disconnect the negative battery cable as de-
from damaging the meter or blowing
the meter’s fuse, if so equipped.
scribed in this chapter.
2. Remove the primary chain case cover and inner
5.
Connect the ammeter between the negative bat-
housing as described in Chapter Five.
tery cable and the negative terminal of the battery
3. If still in place, remove the shaft extension (A,
(Figure 15). If the needle swings even the slightest
Figure 17) and outer spacer (B) from the crank-
amount when the meter is connected, there is a cur-
shaft.
rent draw in the system that will discharge the bat-
4. Slide the rotor (A, Figure 18) off the crankshaft.
tery.
If necessary, insert two wire hooks into the holes in
6. If the current draw is excessive, the probable
the face of the rotor. Slide the rotor off.
causes are:
5. On 1999 models, remove the inner spacer (Fig-
a. Damaged battery.
ure 19) from the crankshaft.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
316
CHAPTER EIGHT
6. Inspect the rotor magnets (Figure 20) for small
bolts, washers or other metal debris that may have
19
been picked up by the magnets. These small metal
bits can cause severe damage to the alternator stator
assembly.
7. Check the inner splines (Figure 21) for wear or
damage. Replace the rotor if necessary.
8. Install by reversing these removal steps.
Stator Removal
1. Remove the rotor as described in this chapter.
2. Disconnect the stator electrical connector (B,
Figure 18) from the wiring harness.
20
NOTE
The following photographs are shown
with the engine removed to better il-
lustrate the steps.
3. Remove the four T27 Torx screws securing the
stator assembly (Figure 22). New Torx screws must
be used on installation.
NOTE
If necessary, spray electrical contact
cleaner or glass cleaner around the
wiring harness grommet to help ease
21
it out of the crankcase boss recepta-
cle.
4. Carefully pull the stator wiring harness and
grommet out of the crankcase boss receptacle (A,
Figure 23) and remove the stator assembly (B).
5. Inspect the stator mounting surface on the crank-
case (Figure 24) for any oil residue that may have
passed by a damaged oil seal. Clean off if necessary.
6. Inspect the stator wires (A, Figure 25) for fray-
ing or damage.
7. Inspect the rubber grommet (B, Figure 25) for
deterioration or hardness.
22
8. Check the stator connector pins (Figure 26) for
looseness or damage.
Stator Installation
1. Apply a light coat of electrical contact cleaner or
glass cleaner to the wiring harness grommet to help
ease it into the crankcase boss receptacle.
2. Insert the electrical harness and grommet into
the crankcase boss receptacle and carefully pull it
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
317
23
27
through until the grommet is correctly seated (Fig-
24
ure 27).
CAUTION
New T27 Torx screws must be in-
stalled. The threadlocking compound
originally applied to the Torx screws
is sufficient for one time use only. If a
8
used Torx screw is installed, it can
work loose and cause engine damage.
3. Move the stator into position on the crankcase
and install four new T27 Torx screws. Tighten the
screws to the specifications in Table 6.
4. Connect the stator electrical connector (B, Fig-
25
ure 18) onto the wiring harness.
5. Install the rotor as described in this chapter.
VOLTAGE REGULATOR
Removal/Installation
NOTE
Always disarm the optional TSSM se-
curity system prior to disconnecting
the battery or the siren will sound.
1. Disconnect the negative battery cable from the
battery as described in this chapter.
26
2. Remove the fuel tank as described in Chapter
Seven.
3. Refer to Electrical Panel in this chapter. Re-
move the cover and outer panel to gain access to the
circuit breaker.
4. Disconnect the voltage regulator black wire
(Figure 28) from the main circuit breaker.
5. Disconnect and remove any cable straps and
clips securing the voltage regulator black wire to the
frame.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
318
CHAPTER EIGHT
28
29
30
ENGINE SENSORS AND SWITCHES
1. Screw
7. Allen bolt
12. Connector-oil pressure
2. Clip
8. Oil pressure switch
switch
3. MAP sensor
9. Oil pressure switch
13. Connector-camshaft
4. Seal
harness connector
position sensor
5. O-ring seal
10. Harness sleeve
(1999-2000)
6. Crankshaft position
11. Connector-crankshaft
14. Camshaft position
sensor
position sensor
sensor (1999-2000)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
ELECTRICAL SYSTEM
319
d. Remove the electrical wires from the connec-
31
tor.
9. Remove the bolts securing the voltage regulator
to the frame. Note the location of the ground strap
on the left side mounting bolt (B, Figure 29).
10. Remove the voltage regulator (C, Figure 29).
Untie the string from the black wire.
11. Install by reversing these removal steps while
noting the following:
a. Tie the string to the voltage regulator black
wire.
b. Carefully pull the string and black wire back
through the frame to the electrical panel. Un-
tie and remove the string.
32
c. Be sure to install the ground wire under the
left side mounting screw (B, Figure 29).
IGNITION SYSTEM
8
The ignition system consists of an ignition coil,
two spark plugs, the ignition module, crankshaft po-
sition sensor
(CKP), manifold absolute pressure
sensor (MAP) and the bank angle sensor (BAS).
The 1999-2000 models are also equipped with the
camshaft position sensor (CMP) that was elimi-
6.
Tie a piece of string to the voltage regulator wire
nated on 2001-on models. Refer to Figure 30 for
at the electrical panel. Tie the other end of the string
the location of all sensors.
to the frame next to the electrical panel. If neces-
The ignition module is located behind the electri-
sary, make a drawing of the wire routing through the
cal panel. It determines the spark advance for cor-
frame. It is easy to forget the routing path after re-
rect ignition timing based on signals from the CKP,
moving the wire.
MAP and BAS (and CMP on 1999-2000 models).
The ignition system fires the spark plugs near top
7. Carefully pull the black wire and string to-
dead center for starting, then varies the spark ad-
ward the front of the motorcycle and through the
vance from 0 to 50° depending on engine speed,
frame. If the wire becomes tight or stuck, do not
crankshaft position, and intake manifold pressure. It
force it.
also regulates the low-voltage circuits between the
NOTE
battery and the ignition coil. The ignition module is
On California models, the connector
a non-repairable item and, if defective, must be re-
is located behind the evaporation
placed.
emission charcoal canister (A, Figure
The crankshaft position sensor (CKP) (Figure
29).
31) is mounted on the front left side of the crankcase
next to the oil filter. The CKP provides engine speed
8. Disconnect the voltage regulator electrical con-
and position data to the ignition module. The sensor
nector from the wiring harness as follows:
is an induction-type pulse generator that generates
a. Remove the screw securing the rubber boot
an alternating current (AC) signal as the 30 teeth of
and electrical connector from the front engine
the flywheel (speed) and the two-tooth gap (refer-
mount.
ence position TDC) pass by the sensor.
b. Slide the rubber boot off the connector.
The MAP sensor (Figure 32) is located on top of
c. Remove the secondary lock off the electrical
the intake manifold. This sensor monitors the intake
wire connectors.
manifold vacuum and sends this information to the
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