BATTERY/CHARGING SYSTEM/ A.C. GENERATOR · PDF fileBystarter G/B W G Resistor 5

14. BATTERY/CHARGING SYSTEM/A.C. GENERATOR

14-0

AGILITY 50

14 FuseRegulator/Rectifier

A.C. Generator

Battery

Regulator/Rectifier

A.C. Generator

Headlight Sw

itch

Y RG

Battery12V4AH

Resistors

14Y

AutoBystarter

G/B W G

Resistor

5Ω5W

CDI


14-1

AGIKITY 50

SERVICE INFORMATIONGENERAL INSTRUCTIONS

• The battery can be charged and discharged repeatedly. If a discharged battery is not used for along time, its service life will be shortened. Generally, the capacity of a battery will decreaseafter it is used for 2～3 years. A capacity-decreased battery will resume its voltage after it isrecharged but its voltage decreases suddenly and then increases when a load is added.

• When a battery is overcharged, some symptoms can be found. If there is a short circuit insidethe battery, no voltage is produced on the battery terminals. If the rectifier won‘t operate, thevoltage will become too high and shorten the battery service life.

• If a battery is not used for a long time, it will discharge by itself and should be recharged every 3months.

• A new battery filled with electrolyte will generate voltage within a certain time and it should berecharged when the capacity is insufficient. Recharging a new battery will prolong its service life.

• Inspect the charging system according to the sequence specified in the Troubleshooting.• Do not disconnect and soon reconnect the power of any electrical equipment because the electronic

parts in the regulator/rectifier will be damaged. Turn off the ignition switch before operation.• It is not necessary to check the MF battery electrolyte or fill with distilled water.• Check the load of the whole charging system.• Do not quick charge the battery. Quick charging should only be done in an emergency.• Remove the battery from the motorcycle for charging.• When replacing the battery, do not use a traditional battery.• When charging, check the voltage with an voltmeter.

The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin andeyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water andget prompt medical attention

SERVICE INFORMATION......................14-1 A.C. GENERATOR CHARGING COIL ...14-6

TROUBLESHOOTING ............................14-2 RESISTOR INSPECTION........................14-6

BATTERY.................................................14-3 A.C. GENERATOR REMOVAL .............14-6

CHARGING SYSTEM .............................14-4 A.C. GENERATOR INATALLATION ...14-8

REGULATOR/RECTIFIER......................14-5


14-2

AGILITY 50

SPECIFICATIONSItem Standard

Capacity/Model 12V−4AHFully charged 13.1VVoltage

(20) Undercharged 12.3VCharging current STD: 0.4A Quick: 4.0A

Battery

Charging time STD: 5～10hr Quick: 30minCapacity 0.144KW/5000rpmLighting coil resistance (20) Yellow～Green 0.1～1.0ΩA.C. GeneratorCharging coil resistance (20) White～Green 0.2～1.2ΩType Single-phase half-wave SCR

13.1～13.9V/5000rpm (Electric tester, tachometer)Lighting 13.1±0.5VRegulator/Rectifier Limit voltage

Charging 14.5±0.5V/5000rpmResistance (20) 5W12ΩResistor Resistance (20) 30W7.5Ω

TORQUE VALUESPulser coil bolt 0.45~0.6kgf-mStator bolt 0.8~1.2kgf-mFlywheel nut 3.5~4.5kgf-mCooling fan bolt 0.8~1.2kgf-m

SPECIAL TOOLSUniversal holderFlywheel puller

TESTING INSTRUMENTSKowa electric testerSanwa electric tester

TROUBLESHOOTINGNo power Intermittent power• Dead battery • Loose battery cable connection• Disconnected battery cable • Loose charging system connection• Fuse burned out • Loose connection or short circuit in• Faulty ignition switch lighting system

Low power Charging system failure• Weak battery • Loose, broken or shorted wire or connector• Loose battery connection • Faulty regulator/rectifier• Charging system failure • Faulty A.C. generator• Faulty regulator/rectifier


14-3

AGIKITY 50

BATTERYREMOVALRemove the battery cover screws on the floorboard.Open the battery cover and remove thebattery by removing the bolt and band.First disconnect the battery negative (-) cableand then the positive (+) cable.

The installation sequence is the reverse ofremoval.

BATTERY VOLTAGE (OPEN CIRCUITVOLTAGE) INSPECTIONRemove the floor board.Open the battery cover and disconnect thebattery cables.Measure the voltage between the batteryterminals.Fully charged : 13.1VUndercharged : 12.3V max.

CHARGINGConnect the charger positive (+) cable to thebattery positive (+) terminal.Connect the charger negative (-) cable to thebattery negative (-) terminal.

Charging current: Standard : 0.4AQuick : 4A

Charging time : Standard : 5～10 hoursQuick : 30 minutes

After charging: Open circuit voltage: 12.8V min.Note: The battery temperature should not

exceed 45during charging.

Battery Cover

When disconnecting the battery positive(+) cable, do not touch the frame withtool; otherwise it will cause short circuitand sparks to fire the fuel.

•Keep flames and sparks away from acharging battery.

•Turn power ON/OFF at the charger, notat the battery terminals to preventsparks near the battery to avoidexplosion.

•Charge the battery according to thet ifi d th b tt

• Quick charging should only be done inan emergency.

• Measure the voltage 30 minutes afterthe battery is charged.

＊

Battery charging inspection must beperformed with a voltmeter.

＊

First connect the positive (+) cable and thenegative (-) cable to avoid short circuit.

Power Lamp (Red)

Charging Lamp (Green)

Red

Black

positive (+) cablenegative (-) cable

battery


14-4

AGILITY 50

CHARGING SYSTEMSHORT CIRCUIT TESTDisconnect the ground wire from the batteryand connect an ammeter across the batterynegative (-) terminal and the ground wire.Turn the ignition switch OFF and check forshort circuit.

If any abnormality is found, check the ignitionswitch and wire harness for short circuit .

CURRENT TESTThis inspection must be performed with anelectric tester when the battery is fullycharged.Warm up the engine for inspection.Connect the electric tester across the batteryterminals. Disconnect the fuse and connect anammeter between the fuse terminals.Attach a tachometer to the engine.Start the engine and gradually increase theengine speed to measure the limit voltage andcurrent.Limit Voltage/Current: 14～15V/0.5A max.

(5000rpm max.)If the limit voltage is not within the specifiedrange, check the regulator/rectifier. ( 14-5)

LIGHTING SYSTEM LIMIT VOLTAGEINSPECTIONRemove the handlebar front cover. ( 2-2)

Limit Voltage: 12～14V/ (5000rpm max.)If the limit voltage is not within the specifiedrange, check the regulator/rectifier. ( 14-5)

Connect the electric tester positive (+)terminal to ground wire and the testernegative (-) terminal to the batterynegative (-) terminal.

＊

Measure the voltage with the electrictester in the AC range.

＊

Terminal

Headlight Wire Coupler

Perform this test with a fully chargedbattery.

＊

(-) Terminal

Battery

(+) Terminal

fuse


14-5

AGIKITY 50

REGULATOR/RECTIFIERMAIN HARNESS CIRCUIT INSPECTIONRemove the front covers. ( 2-2)Remove the regulator/rectifier 4P coupler andcheck for continuity between the wire harnessterminals according to the following :

Item (Wire Color) JudgmentBetween battery (red)and engine ground

Battery hasvoltage

Between ground (green)and engine ground Continuity exists

Between lighting wire(yellow) and engineground (Remove theresistor coupler and autobystarter coupler andturn the lighting switchOFF for inspection)

A.C. generatorstator hasresistance

Between charging coil(white) and engineground

A.C. generatorstator hasresistance

REGULATOR/RECTIFIER INSPECTIONIf the main harness terminals are normal,check the regulator/rectifier coupler for looseconnection and measure the resistancesbetween the regulator/rectifier terminals.

Replace the regulator/rectifier if the readingsare not within the specifications in the table.

Probe⊕Probe(-) White Yellow Red GreenWhite ∞ 3K-50K ∞

Yellow ∞ ∞ 5K-100KRed ∞ ∞ ∞

Green ∞ 5K-50K ∞

• Do not touch the tester probes withyour finger because human body hasresistance.

• Use the following specified testers foraccurate testing. Use of an impropertester in an improper range may givefalse readings.− Kowa Electric Tester− Sanwa Electric Tester− Kowa Electric Tester TH-5H

• Proper range for testing:− Use XKΩ range for Sanwa Tester− Use X100Ω range for Kowa Tester

• If the dry battery in the tester is weak,the readings will be incorrect. In thiscase, check the dry battery.

• The Kowa tester readings are 100times the actual values. Be carefulduring testing.

＊

Regulator/Rectifier

YellowRed

GreenWhite


14-6

AGILITY 50

A.C. GENERATOR CHARGINGCOIL

INSPECTIONDisconnect the A.C. generator 2P connector.Measure the resistance between the A.C.generator white wire and engine ground withan electric tester.Standard: 0.2～1.2Ω(at 20)Replace the A.C. generator charging coil ifthe reading is not within the specifications.

A.C. GENERATOR LIGHTINGCOIL

INSPECTIONDisconnect the A.C. generator 2P connector.Measure the resistance between the A.C.generator yellow wire and engine groundwith an electric tester.Standard: 0.1～1.0Ω (20)Replace the A.C. generator lighting coil if thereading is not within the specifications.

RESISTOR INSPECTIONRemove the front covers. ( 2-2)Measure the resistance between the resistorlead and engine ground.Resistances: 5W12Ω: 11～13Ω

30W7.5Ω: 6～8Ω

A.C. GENERATORREMOVALRemove the right side cover. ( 2-4)Remove the four bolts attaching the coolingfan cover to remove the fan cover.

The inspection of A.C. generator chargingcoil can be made with the engine installed.

＊

The inspection of A.C. generator lightingcoil can be made with the engine installed.

＊

Charging Coil Wire

Lighting Coil Wire

Resistor

Fan Cover


14-7

AGIKITY 50

Remove the cooling fan by removing the fourcooling fan attaching bolts.

Hold the flywheel with an universal holder.Remove the flywheel nut.

Universal Holder

Remove the A.C. generator flywheel usingthe flywheel puller.Remove the woodruff key.

Flywheel Puller

Remove the A.C. generator wire connector.

Cooling Fan

Special

Universal Holder

Flywheel PullerA.C. Generator Wire Connector

Special


14-8

AGILITY 50

Remove the A.C. generator wire set plate.Remove the pulser coil bolts.Remove the A.C. generator wire rubbersleeve and pulser coil from the rightcrankcase.Remove the two bolts and A.C. generatorstator.

A.C. GNERATOR INSTALLATION

Install the A.C. generator stator and pulsercoil onto the right crankcase.Tighten the stator and pulser coil bolts.Torques: Pulser Coil : 0.45~0.6kgf-m

Stator : 0.8~1.2kgf-m

Install the A.C. generator wire rubber sleeveand A.C. generator wire set plate.

A.C. Generator WireRubber Sleeve

Bolts

Woodruff KeyFlywheel

Cooling Fan

Fan Cover

Stator

Bolts

Bolts

Bolts

5.5kg-m

0.9kg-m

0.5kg-m


14-9

AGIKITY 50

Connect the A.C. generator wire connector.

Clean the taper hole in the flywheel off anyburrs and dirt.Install the woodruff key in the crankshaftkeyway.

Install the flywheel onto the crankshaft withthe flywheel hole aligned with the crankshaftwoodruff key.

Hold the flywheel with the universal holderand tighten the flywheel nut.Torque: 3.5~4.5kgf-m

Universal HolderInstall the cooling fan.Torque: 0.8~1.2kgf-m

The inside of the flywheel is magnetic.Make sure that there is no bolt or nutbefore installation.

＊

Special

Cooling Fan

Universal Holder

Woodruff Key

A.C. Generator Wire Connector


14-10

AGILITY 50

Install the fan cover.Install the right side cover. ( 2-4)

Fan Cover

BATTERY/CHARGING SYSTEM/ A.C. GENERATOR · PDF fileBystarter G/B W G Resistor 5

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Transcript of BATTERY/CHARGING SYSTEM/ A.C. GENERATOR · PDF fileBystarter G/B W G Resistor 5