Electrical System

Battery removal

Remove the seats and the battery cover first (see Frame).

1. 1

   Disconnect the negative (−) cable first, then the positive (+).

   ▲ Caution

   Always disconnect the negative (−) terminal first to avoid shorting a spanner against the frame.

2. 2

   Lift the battery out of the case. On installation, connect the positive (+) cable first and the negative (−) last, and coat the terminals with grease to slow corrosion.

Charging condition & refresh charge

1. 1

   Measure the battery terminal voltage with a digital voltmeter. 12.6 V or more = good; below 12.6 V the battery needs a refresh charge.

2. 2

   Slow-charge at the standard rate, then re-check; if it still reads below 12.6 V after charging and a load test, replace the battery.

   Torque1.8 A × 5 – 10 h
3. 3

   Replace a sealed battery only with another sealed type on a bike originally fitted with one.

   ℹ Note

   Fitting a sealed battery where a conventional one was original — or vice-versa — shortens battery life.

Charging-voltage inspection

With a charged battery and a warm engine, measure across the battery terminals.

1. 1

   Start the engine and run it at 3000 rpm; measure the battery voltage — it should rise into the regulated band.

   Torque14.2 – 15.2 V @3000 rpm
2. 2

   If the voltage is far below the band, check the stator-coil resistance (0.18–0.22 Ω) and the alternator no-load output (70–95 V @3000 rpm); if those are good, suspect the regulator/rectifier.

3. 3

   If the voltage is well above the band, the regulator/rectifier is overcharging — replace it.

   ▲ Caution

   Do not disconnect the battery while the engine is running; the resulting voltage spike can destroy the regulator/rectifier and the DFI ECU.

Ignition-coil & crankshaft-sensor resistance

1. 1

   Measure the ignition-coil primary winding (≈1.9–2.5 Ω) and the secondary winding (≈10–16 kΩ) with the hand tester; a reading far outside the band means a faulty coil.

2. 2

   Measure the crankshaft-sensor resistance (420–520 Ω); its peak voltage should be 3.0 V or more when cranking.

3. 3

   Set the spark-plug gap on installation.

   Torquegap 1.0 – 1.1 mm

   ℹ Note

   The IC igniter lives inside the ECU and is not separately serviceable — diagnose it by elimination once the coils, plugs and crank sensor check good.

Starter-motor inspection

1. 1

   Measure each brush; replace the brushes as a set once any is worn to the limit.

   Torquebrush 12.5 → 5 mm limit
2. 2

   Measure the commutator outside diameter; replace the armature if it is worn below the limit, and clean a dirty commutator (do not undercut the mica below flush).

   Torquecommutator 28 → 27 mm limit
3. 3

   On reassembly torque the terminal nut (9.8 N·m) and the assembly bolts (4.9 N·m); on the bike torque the mounting bolts to 9.8 N·m.

Tail/brake light bulb

1. 1

   Turn the bulb socket counter-clockwise and pull it out; align the new socket’s arrow with the housing arrow and turn clockwise.

2. 2

   Refit the unit and torque the mounting nuts.

   Torque5.9 N·m