ELECTRICAL SYSTEM 16-1
Electrical System
Table of Contents
Parts Location......................................................................................................................... |
16-3 |
|
|
Exploded View........................................................................................................................ |
16-4 |
|
|
Specifications ......................................................................................................................... |
16-10 |
|
|
Special Tools and Sealant ...................................................................................................... |
16-11 |
|
|
Wiring Diagram (Canada)....................................................................................................... |
16-12 |
|
|
Wiring Diagram (Australia) ..................................................................................................... |
16-14 |
|
|
Wiring Diagram (Other than Canada, Australia and Malaysia)............................................... |
16-16 |
|
|
Wiring Diagram (Malaysia) ..................................................................................................... |
16-18 |
|
|
Precautions............................................................................................................................. |
16-20 |
|
|
Electrical Wiring...................................................................................................................... |
16-22 |
|
|
Wiring Inspection .............................................................................................................. |
16-22 |
|
|
Battery .................................................................................................................................... |
16-23 |
|
|
Battery Removal ............................................................................................................... |
16-23 |
|
|
Battery Installation ............................................................................................................ |
16-23 |
|
|
Electrolyte Filling............................................................................................................... |
16-23 |
|
|
Initial Charge..................................................................................................................... |
16-25 |
|
|
Precautions ....................................................................................................................... |
16-26 |
|
|
Interchange ....................................................................................................................... |
16-27 |
|
|
Charging Condition Inspection.......................................................................................... |
16-27 |
|
|
Refreshing Charge............................................................................................................ |
16-27 |
|
|
Charging System .................................................................................................................... |
16-29 |
|
|
Alternator Cover Removal................................................................................................. |
16-29 |
|
|
Alternator Cover Installation.............................................................................................. |
16-29 |
|
|
Stator Coil Removal.......................................................................................................... |
16-29 |
|
|
Stator Coil Installation ....................................................................................................... |
16-30 |
|
|
Alternator Rotor Removal ................................................................................................. |
16-30 |
|
|
Alternator Rotor Installation .............................................................................................. |
16-30 |
|
|
.........................................................................................................Alternator Inspection |
16-32 |
16 |
|
Regulator/Rectifier Inspection........................................................................................... |
16-33 |
|
|
|
|
||
Charging Voltage Inspection............................................................................................. |
16-35 |
|
|
Ignition System ....................................................................................................................... |
16-37 |
|
|
Crankshaft Sensor Removal............................................................................................. |
16-37 |
|
|
Crankshaft Sensor Installation .......................................................................................... |
16-38 |
|
|
Crankshaft Sensor Inspection........................................................................................... |
16-39 |
|
|
Crankshaft Sensor Peak Voltage Inspection..................................................................... |
16-39 |
|
|
Timing Rotor Removal ...................................................................................................... |
16-40 |
|
|
Timing Rotor Installation ................................................................................................... |
16-40 |
|
|
Camshaft Position Sensor Removal ................................................................................. |
16-40 |
|
|
Camshaft Position Sensor Installation .............................................................................. |
16-40 |
|
|
Camshaft Position Sensor Inspection ............................................................................... |
16-41 |
|
|
Camshaft Position Sensor Peak Voltage Inspection......................................................... |
16-41 |
|
|
Stick Coil (Ignition Coil together with Spark Plug Cap) Removal...................................... |
16-42 |
|
|
Stick Coil (Ignition Coil together with Spark Plug Cap) Installation................................... |
16-42 |
|
|
Stick Coil (Ignition Coil together with Spark Plug Cap) Inspection.................................... |
16-43 |
|
|
Stick Coil Primary Peak Voltage ....................................................................................... |
16-43 |
|
|
Spark Plug Removal ......................................................................................................... |
16-44 |
|
|
16-2 ELECTRICAL SYSTEM
|
|
Spark Plug Installation ...................................................................................................... |
16-44 |
Spark Plug Inspection ....................................................................................................... |
16-44 |
Spark Plug Gap Inspection ............................................................................................... |
16-44 |
Interlock Operation Inspection .......................................................................................... |
16-45 |
IC Igniter Inspection .......................................................................................................... |
16-46 |
Electric Starter System ........................................................................................................... |
16-49 |
Starter Motor Removal...................................................................................................... |
16-49 |
Starter Motor Installation................................................................................................... |
16-49 |
Starter Motor Disassembly................................................................................................ |
16-49 |
Starter Motor Assembly .................................................................................................... |
16-50 |
Brush Inspection ............................................................................................................... |
16-51 |
Commutator Cleaning and Inspection............................................................................... |
16-51 |
Armature Inspection.......................................................................................................... |
16-51 |
Brush Lead Inspection ...................................................................................................... |
16-52 |
Brush Plate and Terminal Bolt Inspection ......................................................................... |
16-52 |
Starter Relay Inspection.................................................................................................... |
16-52 |
Lighting System ...................................................................................................................... |
16-54 |
Headlight Beam Horizontal Adjustment ............................................................................ |
16-54 |
Headlight Beam Vertical Adjustment................................................................................. |
16-54 |
Headlight Bulb Replacement ............................................................................................ |
16-54 |
Headlight Removal/Installation ......................................................................................... |
16-55 |
City Light Bulb Replacement (European Model)............................................................... |
16-56 |
Turn Signal Light Bulb Replacement ................................................................................ |
16-58 |
Turn Signal Relay Inspection ............................................................................................ |
16-60 |
Tail/Brake Light (LED) Removal........................................................................................ |
16-60 |
Tail/Brake Light (LED) Installation..................................................................................... |
16-61 |
Radiator Fan System.............................................................................................................. |
16-62 |
Fan System Circuit Inspection .......................................................................................... |
16-62 |
Fan Motor Inspection ........................................................................................................ |
16-62 |
Meter, Gauge, Indicator Unit................................................................................................... |
16-64 |
Meter Unit Removal .......................................................................................................... |
16-64 |
Meter, Gauge Disassembly............................................................................................... |
16-64 |
Electronic Combination Meter Unit Inspection .................................................................. |
16-65 |
Switches and Sensors ............................................................................................................ |
16-74 |
Brake Light Timing Inspection........................................................................................... |
16-74 |
Brake Light Timing Adjustment ......................................................................................... |
16-74 |
Switch Inspection .............................................................................................................. |
16-74 |
Radiator Fan Switch Inspection ........................................................................................ |
16-74 |
Water Temperature Sensor Inspection ............................................................................. |
16-75 |
Speed Sensor Inspection.................................................................................................. |
16-76 |
Fuel Level Sensor Inspection............................................................................................ |
16-78 |
Fuel Reserve Switch Inspection........................................................................................ |
16-78 |
Diode (Rectifier) Inspection............................................................................................... |
16-79 |
Junction Box........................................................................................................................... |
16-80 |
Junction Box Fuse Circuit Inspection................................................................................ |
16-80 |
Starter Circuit/Headlight Relay Inspection ........................................................................ |
16-81 |
Diode Circuit Inspection .................................................................................................... |
16-82 |
Fuse........................................................................................................................................ |
16-83 |
30 A Main Fuse Removal.................................................................................................. |
16-83 |
Junction Box Fuse Removal ............................................................................................. |
16-83 |
Fuse Installation................................................................................................................ |
16-83 |
15 A ECU Fuse Removal.................................................................................................. |
16-83 |
Fuse Inspection................................................................................................................. |
16-84 |
16-4 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-5
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Meter mounting screws |
1.2 |
0.12 |
10 in·lb |
|
|
2 |
Tail/brake light mounting screws |
1.2 |
0.12 |
10 in·lb |
|
|
3 |
License plate light mounting screws |
1.2 |
0.12 |
10 in·lb |
|
|
4 |
Front brake light switch screw |
1.0 |
0.10 |
9 in·lb |
|
|
5 |
Starter locknut switch screws |
– |
– |
– |
L |
|
6 |
Left switch housing screws |
3.5 |
0.36 |
31 in·lb |
|
|
7 |
Right switch housing screws |
3.5 |
0.36 |
31 in·lb |
|
|
8 |
Headlight mounting bolts |
5.9 |
0.60 |
52 in·lb |
|
9. Tail/brake lights (LED)
10. Vibration Resistance Bulb
11. Install the rear brake spring as shown. Longer Side [A]
L: Apply a non–permanent locking agent.
AU: Australia
CA: Canada
EUR: European Community
16-6 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-7
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Water temperature sensor |
25 |
2.5 |
18 |
SS |
|
2 |
Spark plugs |
13 |
1.3 |
113 in·lb |
|
|
3 |
Alternator lead holding plate bolt |
11 |
1.1 |
95 in·lb |
L |
|
4 |
Starter motor mounting bolts |
11 |
1.1 |
95 in·lb |
|
|
5 |
Stator coil bolts |
11 |
1.1 |
95 in·lb |
|
|
6 |
Alternator rotor bolt |
110 |
11 |
81 |
|
|
7 |
Starter motor clutch bolts |
12 |
1.2 |
104 in·lb |
L |
|
8 |
Alternator cover bolts |
11 |
1.1 |
95 in·lb |
|
|
9 |
Crankshaft sensor bolts |
5.9 |
0.60 |
52 in·lb |
|
|
10 |
Crankshaft sensor cover bolts |
11 |
1.1 |
95 in·lb |
|
|
11 |
Timing rotor bolt |
39 |
4.0 |
29 |
|
|
12 |
Camshaft position sensor bolt |
12 |
1.2 |
104 in·lb |
L |
|
13 |
Radiator fan switch |
18 |
1.8 |
13 |
|
|
14 |
Starter relay cable terminal bolts |
3.9 |
0.40 |
35 in·lb |
L |
|
15 |
Oil pressure switch terminal bolt |
1.5 |
0.15 |
13 in·lb |
G |
|
16 |
Oil pressure switch |
15 |
1.5 |
11 |
SS |
17. Radiator fan
18. Crankshaft sensor
19. Camshaft position sensor
20. Starter relay/main fuse
21. Stick coils
22. Ignition switch G: Apply grease.
L: Apply a non-permanent locking agent.
M: Apply molybdenum disulfide grease.
SS: Apply silicone sealant.
16-8 ELECTRICAL SYSTEM
Exploded View
ELECTRICAL SYSTEM 16-9
Exploded View
|
|
|
|
|
|
|
No. |
Fastener |
|
Torque |
|
Remarks |
|
N·m |
kgf·m |
ft·lb |
||||
|
|
|
||||
1 |
Regulator/rectifier bolts |
6.9 |
0.70 |
61 in·lb |
|
|
2 |
Fuel level sensor bolts |
6.9 |
0.70 |
61 in·lb |
|
|
3 |
Side stand switch bolt |
8.8 |
0.90 |
78 in·lb |
L |
|
4 |
Neutral switch |
15 |
1.5 |
11 |
|
|
5 |
Speed sensor bolt |
6.9 |
0.70 |
61 in·lb |
L |
|
6 |
Speed sensor cover bolts |
6.9 |
0.70 |
61 in·lb |
L |
|
7 |
Regulator/rectifier bracket bolts |
6.9 |
0.70 |
61 in·lb |
|
|
8 |
Engine ground cable terminal bolt |
9.8 |
1.0 |
87 in·lb |
|
9.Turn signal relay
10.Junction box
11.ECU (Electrical Unit Control)
12.15 A ECU fuse
13.Fuel reserve switch
14.Diode (Rectifier)
15.Speed sensor
16.Regulator/rectifier
17.Battery 12 V 8 Ah
L:Apply a non-permanent locking agent.
16-10 ELECTRICAL SYSTEM
Specifications
|
|
|
|
Item |
|
Standard |
|
Battery: |
|
|
|
Type |
Sealed Battery |
||
Capacity |
12 V 8 Ah |
||
Voltage |
12.6 V or more |
||
Charging System: |
|
|
|
Type |
Three-phase AC |
||
Alternator output voltage |
42 V or more |
||
Stator coil resistance |
0.3 |
0.4 Ω |
|
Charging voltage |
14.7 ±0.5 V |
||
(regulator/rectifier output voltage) |
|
|
|
Ignition System: |
|
|
|
Crankshaft sensor resistance |
376 |
564 Ω |
|
Crankshaft sensor peak voltage |
1.9 V or more |
||
Camshaft Position Sensor resistance |
400 |
460 Ω |
|
Camshaft Position Sensor peak voltage |
0.2 V or more |
||
Interlock Operation Voltage |
4 V or more |
||
Stick coil: |
|
|
|
Primary winding resistance |
1.04 |
1.56 Ω |
|
Secondary winding resistance |
10.8 |
16.2 kΩ |
|
Primary peak voltage |
88 V or more |
||
Spark plug: |
|
|
|
Spark plug gap |
0.7 |
0.8 mm (0.028 0.031 in.) |
|
Electric Starter System: |
|
|
|
Starter motor: |
|
|
|
Brush length |
12 mm (0.47 in.) (Service limit: 8.5 mm, 0.33 in.) |
||
Commutator diameter |
28 mm (1.10 in.) (Service limit: 27 mm, 1.06 in.) |
||
Switch and Sensor: |
|
|
|
Rear brake light switch timing |
ON after about 10 mm pedal travel |
||
Engine oil pressure switch connections |
When engine is stopped: ON |
||
|
When engine is running: OFF |
||
Fan switch connections |
|
|
|
Rising temperature |
From OFF to ON @ 93 103°C (199 217°F) |
||
Falling temperature |
Fan stops with the temperature 3 ~ 8°C (38 46°F) |
||
lower than the operation temperature range. |
|||
|
|||
|
ON: Less than 0.5 Ω |
||
|
OFF: More than 10 MΩ |
||
Water temperature sensor resistance |
in the text |
||
Fuel level sensor resistance: |
|
|
|
Fuel position |
4 ~ 10 Ω |
||
Empty position |
90 ~ 100 Ω |
||