Page 140 of 457
3-63
Relationship between the open-circuit voltage
and the charging time at 20C
Open-circuit voltage (V)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 13.0
12.5
12.0
11.5
5 6.5 10
Charging time (hours)
Ambient
temperature
20C
Open-circuit voltage (V)
Charging condition of the battery (%)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
CAUTION:
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
1. Remove:
rider seat
Refer to “SEATS”.
2. Disconnect:
battery leads
(from the battery terminals)
First, disconnect the negative battery lead
1, and then the positive battery lead 2.
3. Remove:
battery
4. Check:
battery charge
a. Connect a pocket tester to the battery termi-
nals.
Pocket tester
90890-03112, YU-3112
Positive tester probe
positive battery terminal
Negative tester probe
negative battery terminal
The charge state of an MF battery can be
checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).
No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 30%
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3-64
Charging
Ambient temperature 20C
Open-circuit voltage (V)
Check the open-circuit
voltage.Time (minutes)
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
WARNING
CAUTION:
5. Charge:
battery
(refer to the appropriate charging method il-
lustration)
Do not quick charge a battery.
Never remove the MF battery sealing caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to remove
it from the motorcycle. (If charging has to
be done with the battery mounted on the
motorcycle, disconnect the negative bat-
tery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate heat
in the contact area and a weak clip spring
may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
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Page 142 of 457
3-65
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charged and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
By turning the charging
voltage adjust dial, set the
charging voltage at 20 24 V.
Adjust the voltage so that the
current is at the standard
charging level.Monitor the amperage for
3 5 minutes to check if the
standard charging current is
reached.
Set the time according to the
charging time suitable for the
open-circuit voltage.
Refer to “Battery condition
checking steps”.If the current does not
exceed the standard
charging current after 5
minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the
charging current after a lapse of 5 hours. If there is any change in the
amperage, readjust the voltage to obtain the standard charging
current.
Measure the battery open-circuit voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.YES NO
YES
NONOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Set the charging voltage at 16 17 V.
(If the setting is lower, charging will be
insufficient. If too high, the battery will
be over-charged.)
Charging method using a variable-current (voltage) charger
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3-66
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
Measure the open-circuit
voltage prior to charging.
Connect a charger and
AMP meter to the battery
and start charging.
Make sure that the current
is higher than the standard
charging current written on
the battery.
Charge the battery until the battery’s
charging voltage is 15 V.This type of battery charger cannot
charge the MF battery. A variable
voltage charger is recommended.
Measure the battery open-circuit
voltage after leaving the battery
unused for more than 30 minutes.
12.8 V or more --- Charging is
complete.
12.7 V or less --- Recharging is
required.
Under 12.0 V --- Replace the battery.
Set the charging time at 20 hours
(maximum).
YES NO
NOTE:
Voltage should be measured 30
minutes after the machine is stopped.
NOTE:
Charging method using a constant voltage charger
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Page 144 of 457
3-67
CHECKING AND CHARGING THE BATTERY /
CHECKING THE FUSESCHK
ADJ
CAUTION:
CAUTION:
NOTE: 6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
First, connect the positive battery lead
1,
and then the negative battery lead
2.
8. Check:
battery terminals
Dirt Clean with a wire brush.
Loose connection Connect properly.
9. Lubricate:
battery terminals
Recommended lubricant
Dielectric grease
10. Install:
rider seat
Refer to “SEATS”.
EAS00181
CHECKING THE FUSES
The following procedure applies to all of the
fuses.
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
front cowling inner panel (left)
Refer to “COWLINGS”.
rider seat
Refer to “SEATS”.
2. Check:
fuse
a. Connect the pocket tester to the fuse and
check the continuity.
Set the pocket tester selector to “Ω 1”.
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Page 221 of 457
4-74
SWINGARM AND DRIVE CHAINCHAS
CAUTION:
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
This motorcycle has a drive chain with small
rubber O-rings
1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean the
drive chain. High-pressure methods could
force dirt or water into the drive chain’s in-
ternals, and solvents will deteriorate the O-
rings. A coarse brush can also damage the
O-rings. Therefore, use only kerosene to
clean the drive chain. Don’t soak drive chain
in kerosine more them ten minutes. O-ring is
damage by kerosine.
4. Check:
O-rings
1
Damage Replace the drive chain.
drive chain rollers
2
Damage / wear Replace the drive chain.
drive chain side plates
3
Damage / wear Replace the drive chain.
Cracks Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:
drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
ProCarManuals.com
Page 227 of 457
5-5
Order Job / Part Q’ty Remarks
1
2Disconnecting the leads and hoses
Fuel tank
Air filter case
Throttle body assembly
Engine oil
Oil cooler
Air cut-off valve
Starter motor
Battery negative lead
Battery positive lead1
1Disconnect the parts in the order listed.
Refer to “FUEL TANK” in chapter 3.
Refer to “AIR FILTER CASE” in chapter 3.
Refer to “THROTTLE BODIES” in
chapter 7.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Refer to “OIL COOLER” in chapter 6.
Refer to “AIR INDUCTION SYSTEM” in
chapter 7.
Refer to “STARTING SYSTEM” in
chapter 7.
ENGINEENG
LEADS AND HOSES
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Page 228 of 457
5-6
Order Job / Part Q’ty Remarks
3
4
5
6
7
8
9
10Clutch cable
Ground lead
Stator coil assembly coupler
Crankshaft position sensor lead coupler
Oil level switch connector
Neutral switch connector
Speed sensor coupler
Cylinder identification sensor coupler1
2
1
1
1
1
1
1First, disconnect the negative battery
lead, and then the positive battery lead.
For connecting, reverse the disconnec-
tion procedure.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
CAUTION:
ENGINEENG
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