ELECTRICAL SYSTEM 16-25

Battery
Charging Condition Inspection
żBattery charging condition can be checked by measuring
battery terminal voltage with a digital voltmeter [A].
• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Battery Cable Caps (see Battery Removal)
• Disconnect the battery terminals.
CAUTION
Be sure to disconnect the negative (–) lead first.

• Measure the battery terminal voltage.

NOTE
żMeasure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.8 V or more, no refresh charge is re-
quired, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard: 12.8 V or more
Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Good [C]
Refresh charge is required [D]

Refreshing Charge
• Remove
ter).
the battery [A] (see Battery Removal in this chap-

• Do refresh charge by following method according to the

battery terminal voltage.
WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.

Terminal Voltage: 11.5 ∼ less than 12.8 V

Standard Charge 0.9 A × 5 ∼ 10 h (see following chart)
Quick Charge 4A×1h

CAUTION
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.

Terminal Voltage: less than 11.5 V

Charging Method: 0.9 A × 20 h
16-26 ELECTRICAL SYSTEM
Battery
NOTE
żIncrease the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 min-
utes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]

• Determine the battery condition after refresh charge.

żDetermine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria Judgement
12.8 V or higher Good
12.0 ∼ lower than 12.8 V Charge insufficient ĺ Recharge
lower than 12.0 V Unserviceable ĺ Replace
 ELECTRICAL SYSTEM 16-27
Charging System
Alternator Cover Removal
• Remove:
Left Center Fairing (see Center Fairing Removal in the
Frame chapter)
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Coolant Reserve Tank (see Coolant Reserve Tank Re-
moval in the Cooling System chapter)
Alternator Lead Connector [A]

• Remove:
Bolts [A]
Cover [B]

Alternator Cover Installation

• crankcase
Apply silicone sealant to the alternator lead grommet and
halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Check that dowel pins [B] are in place on the crankcase.
• Tighten: new gasket and the alternator cover.
Install a
•
Torque - Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 104
in·lb)

Stator Coil Removal

• Remove:
Alternator Cover (see Alternator Cover Removal in this
chapter)
Holding Plate Bolts [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
• Remove the stator coil [D] from the alternator cover.

Stator Coil Installation

• the
Apply a non-permanent locking agent to the threads of
stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
• nator
Apply silicone sealant to the circumference of the alter-
lead grommet, and fit the grommet into the notch of
the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
16-28 ELECTRICAL SYSTEM
Charging System

• Secure the alternator lead with a holding plate, and apply

a non-permanent locking agent to the threads of the plate
bolts and tighten them.
Torque - Alternator Lead Holding Plate Bolts: 6.9 N·m (0.70
kgf·m, 61 in·lb)
• Install
tion).
the alternator cover (see Alternator Cover Installa-

Alternator Rotor Removal

• Remove:
Alternator Cover (see Alternator Cover Removal)
Starter Idle Gear and Shaft
• Wipe oil off the outer circumference of the rotor.
• Hold the alternator rotor steady with the flywheel holder
[A], and remove the rotor bolt [B].
Special Tool - Flywheel Holder: 57001-1313

• Using the flywheel puller [A], remove the alternator rotor

from the crankshaft.
Special Tool - Flywheel Puller, M38 × 1.5: 57001-1405

CAUTION
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.

Alternator Rotor Installation

• Using a cleaning fluid, clean off any oil or dirt on the fol-
lowing portions and dry them with a clean cloth.
Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
• Apply a thin coat of molybdenum disulfide grease to the
crankshaft [C].

• Install the starter gear [A] and washer [B].

• there. clean the crankshaft tapered portion [C] and dry
Again,
 ELECTRICAL SYSTEM 16-29
Charging System

• Install the alternator rotor [A] while turning [B] it counter-

clockwise.

• Install the washer [A].

NOTE
żConfirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.

• Install the rotor bolt [B] and tighten it with 70 N·m (7.0
kgf·m, 52 ft·lb) of torque.
• Remove the rotor bolt.
• If the rotortightening
Check the torque with flywheel puller [C].
is not pulled out with 40 N·m (4.1 kgf·m, 30
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 40 N·m (4.1 kgf·m, 30
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
• Tighten the alternator rotor bolt while holding the alterna-
tor rotor steadily with the flywheel holder.
Special Tool - Flywheel Holder: 57001-1313
Torque - Alternator Rotor Bolt: 108 N·m (11 kgf·m, 80 ft·lb)

• shaft
Apply a thin coat of molybdenum disulfide grease to the
[A], and install it and starter idle gear [B].
• tion). the alternator cover (see Alternator Cover Installa-
Install

Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.
16-30 ELECTRICAL SYSTEM
Charging System

• To check the alternator output voltage, do the following

procedures.
żTurn off the ignition switch.
żRemove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
żDisconnect the alternator lead connector [A].
żConnect the hand tester as shown in the table 1.
żStart the engine.
żRun it at the rpm given in the table 1.
żNote the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Tester Connections Reading
Range Tester (+) to Tester (–) to @4 000 rpm
AC 250 V One Black lead Another Black lead 42 V or more

If the output voltage shows the value in the table, the al-
ternator operates properly.
If the output voltage shows a much higher than the value
in the table, the regulator/rectifier is damaged. A much
lower reading than that given in the table indicates that
the alternator is defective.
•Check the stator coil resistance as follows.
żStop the engine.
żConnect the commercially available tester as shown in the
table 2.
żNote the readings (total 3 measurement).
Table 2 Stator Coil Resistance
Tester Connections
Reading
Range Tester (+) to Tester (–) to
×1ȍ One Black lead Another Black lead 0.3 ∼ 0.4 ȍ
If there is more resistance than shown in the table, or
no tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
• Using the highest resistance range of the hand tester,
measure the resistance between each of the black leads
and chassis ground.
Any hand tester reading less than infinity (’) indicates a
short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.
Special Tool - Hand Tester: 57001-1394
 ELECTRICAL SYSTEM 16-31
Charging System
Regulator/Rectifier Removal
• Remove:
Bolts [A]
Regulator/Rectifier [B]

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Connector [A]

Regulator/Rectifier Inspection
Rectifier Circuit Check
•Check the rectifier resistance as follows.
•Disconnect the regulator/rectifier connector.
•Connect the hand tester (special tool) to the regulator/rec-
tifier as shown in the table, and check the resistance in
both directions of each diode in the rectifier following the
table.
The resistance should be low in one direction and more
than ten times as much in the other direction. If any two
leads are low or high in both directions, the rectifier is
defective and the regulator/rectifier must be replaced.
NOTE
żThe actual meter reading varies with the meter used
and the individual rectifier, but, generally speaking the
lower reading should be from zero to one half the scale.

Connections Tester
No. Reading
Tester (+) Tester (–) Range
1 BK1
2 BK2 BK/BL ’
3 BK3
4 BK1
5 BK2 BK/W
6 BK3 × 10 ȍ
1/2 scale
or
7 BK1 or less
× 100 ȍ
8 BK/BL BK2
9 BK3
10 BK1
11 BK/W BK2 ’
12 BK3
16-32 ELECTRICAL SYSTEM
Charging System
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries
and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).
CAUTION
The test light works as an indicator and also a cur-
rent limiter to protect the regulator/rectifier from ex-
cessive current. Do not use an ammeter instead of
a test light.

•żDo the 1st step regulator circuit test.

Connect the test light and the 12 V battery to the regula-
tor/rectifier as shown.
żCheck BK1, BK2, and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

•żDo the 2nd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the “1st step regulator circuit test”.
żApply 12 V to the BK/R terminal.
żCheck BK1, BK2, and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective.
Replace it.
If the test light does not turn on, continue the test.

•żDo the 3rd step regulator circuit test.

Connect the test light and the 12 V battery in the same
manner as specified in the “1st step regulator circuit test”.
żMomentarily apply 24 V to the BK/R terminal by adding a
12 V battery.
żCheck BK1, BK2, and BK3 terminals respectively.
CAUTION
Do not apply more than 24 volts. If more than 24
volts is applied the regulator/rectifier may be dam-
aged. Do not apply 24 V more than a few seconds.
If 24 volts is applied for more than a few seconds,
the regulator/rectifier may be damaged.
If the test light did not light when the 24 V was applied
momentarily to the BK/R terminal, the regulator/rectifier
is defective. Replace it.
If the regulator/rectifier passes all of the tests described,
it may still be defective. If the charging system still does
not work properly after checking all of the components
and the battery, test the regulator/rectifier by replacing it
with a known good unit.
 ELECTRICAL SYSTEM 16-33
Charging System
Charging Voltage Inspection
• Check the battery condition (see Charging Condition In-
spection).
• Warm up the engine to obtain actual alternator operating
conditions.
• Remove:
Front Seat (see Front Seat Removal in the Frame chap-
ter)
Caps
• Check that the ignition switch is turned off, and connect
the hand tester [A] as shown in the table.
Special Tool - Hand Tester: 57001-1394
• Start the engine, and note the voltage readings at vari-
ous engine speeds with the headlight turned on and then
turned off. (Disconnect the headlight connector in the up-
per fairing.) The readings should show nearly battery volt-
age when the engine speed is low, and, as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Charging Voltage
Connections
Tester Range Reading
Tester (+) to Tester (–) to
DC 25 V Battery (+) Battery (–) 14.2 ∼ 15.2 V

• Turn off the ignition switch to stop the engine, and discon-
nect the hand tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.
16-34 ELECTRICAL SYSTEM
Charging System
Charging System Circuit

1. Ignition Switch
2. Alternator
3. Regulator/rectifier
4. Main Fuse 30 A
5. Battery 12 V 8 Ah
6. Load