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6-1 ELECTRIC STARTING SYSTEM

A. Starter Motor
1. Circuit diagram.

r

RELAY SWITCH

STARTER

r--i
STARTER
SWITCH

BATTERY

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T

2. Removal (see Section 3-2, Engine Disassembly).

3. Inspection and repair
a. Check the outer surface of the commutator.
If i t s surface is dirty, clean with No. 600
grit sand paper.

b. The mica insulation between commutator
segments should be 0.5~0.8mm (0.02~0.03")
below the segment level. If not, scrape t o proper limits with appropriately shaped tool. (A
hack saw blade can be ground t o fit.)

I

I

Coil Resistance

Armature coil

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0.007 fi (20°C)

Field Coil

I

0.01

fi (20°C)

1

I

d. Check the front and rear cover bearings for
damage. I f damaged, the starter assembly
must be replaced.
e. Check brush length. Replace brush if at, or
near, limits.

MICA UNDERCUT
0.5-0.8mm
(0.02-0.03 in.)

COMMUTATOR

c. Check the armature and field coil for shorting
and insulation. Replace armature as required.

Accelerate engine to approximately 2. A. Check brush spring pressure. Replace spring if it is weak. Use (ohms x 1 ) scale on tester. d. MAIN B. Disconnect starter relay leads a t the relay. then perform the tests in step 2.damaging the semiconductors. I f the relay does not click.5±0. REGULATOR b.22 in. c. a. NOTE: Never disconnect wires from the battery while the generator is in operation. Connect pocket tester leads to the relay terminals (ohms x 1 scale). If the relay clicks but the scale does not read zero.C. voltmeter t o the battery terminals. Push starter button. b.I Minimum brush lenoth: 5. Turn ignition off.) I f. Generator 1. e. Turn ignition on ("I" position) and engine stop switch t o "RUN". Connect D. Starter Relay Switch A C GENERATOR 1. If the indicated voltage cannot be reached.5V I d. Checking method. Charging Circuit Diagram c. B. If the battery is disconnected. Start engine. Inspection a. The relay should click once and the scale should read zero ohms.5mm (0.000 rpm or more and check generated voltage. blue/white).5 ohms. the relay should be replaced. If there is more resistance. 6-2 CHARGING SYSTEM A. The resistance between these wires should be no more than 3. the voltage across the generator terminals will increase. I Generated voltage: 14.C. . the relay must be replaced. check the wires from the starter button and the battery (red/white.

600). thoroughly clean contact points with contact point-cleaner. . If resistance is out of specification.2. a D.3~0. First adjust the core gap and then the point gap. Core gap . .C. They are connected as illustrated. Check the coil connections.-1 Check the resistance between terminals. Remove the regulator from the frame.04 ohms ± 10% a t 20°C (68° F) CORE GAP Stator coil resistance: 7 ARMATURE LOWER / (W1-W2. . . I f the coil connections are good. 500 or No. . W3-W1) 0. . they should be smoothed with sand paper (No. . it should be adjusted. . . then the coil is broken inside and it should be replaced. Voltage Regulator The regulator's function is t o passa controlled amount of current through the field windings which creates a magnetic field that produces a charging voltage in the three stator windings. I f the point surfaces are rough.0. . When adjusting the regulator.0. b.6~1. and tachometer are necessary. . Check the core and points for gap adjustment.0mm Point gap. Field coil resistance: (Green-Black) 4. . and adjustment should be made in the following sequence: 1 white white a. ammeter. LOCKNUT -1 \ II \ COIL . After sandpapering. If any gap is incorrect. . coil is broken.48 ohms ± 10% a t 20° C (68° F) C. II ' RECTIFIER I I 1. Resistance test of field coil and stator coil. . .4mm FIELD COIL TO O I L PRESSURE SWITCH NOTE: No adjustment is required for the yoke gap. . W2-W3. . and check the contact points. voltmeter.

c* ABOUT 0.-CORE - . the generated voltage shows slight fluctuations as illustrated below.000 km (8.5 volt. I f the voltage increase is more or less than 0. Tester should indicate 14. CORE GAP (SMALL) I ENGINE SPEED (R. Start engine. Remove the RED wire from theconnector. white u Continuity: Con Discontinuity: Dis I CAUTION: Take care t o not short the red wire. thevoltage fluctuates slightly. NOTE: The regulator should bechecked every 12.5volt increase.5~15V (DC). II I Dl Con inf I I I D4 D5 D6 inf inf I V B D3 - I : I :I ::: I :I I z I ::: I I I I inf inf inf inf B W W B CO" u E U CO" CO" E inf CO" inf inf V E E CO" V CO" CO" inf inf CO" inf inf W E E W inf inf CO" inf CO" CO" CO" .M. Checking Silicon Rectifier 1. I . Inside the housing isascrewthat pushes against a flat spring steel plate.' GAP (LARGE) -_.. Charging voltage output can be controlled a t the regulator. After the adjustment.) c.5V ~ . D. Before starting engine. Check silicon rectifier as specified using the Yamaha Pocket Tester. Connect pocket tester (DC20V) red tester lead (+) t o red wire from rectifier.) of operation. . 1 black. When the generator speed increases from low (the lower contact is in operation) t o high (the upper contact is in operation). .P. the core gap should be readjusted. This is the adjusting screw. disconnect wire connector (coupler) containing 5 wires from rectifier (1 red.000 mi. If t h i s wire i s shorted.. d. the rectifier could be damaged... If the voltageshowsa 0. 3 white). the adjustment is considered t o be correct. but this is a normal phenomenon.. Connect tester black(-)to good ground.

c. b. a. but lack of care as described below will shorten the life of the battery. I Electrolyte Specific gravity: 1. I f battery sulfation (white accumulation) occurs on plates due to lack of battery electrolyte. 6-3 IGNITION SYSTEM A.Even if only one element is broken. Governor Assembly d. nor will it advance t o i t s fullest extent. The service life of a battery i s usually 2 t o 3 years. remove the battery and have it stored. Never connect the rectifier directly t o the battery t o make a continuity check. the battery should be replaced. Inspection a. The following instructions should be observed: b. I B. it should be replaced: 1) The voltage will not rise to a specific value even after many hours of charging. the battery should be replaced. Special care should be taken t o avoid a short circuit and/or incorrect connection of the positive and negative leads a t the battery. 1. Negligence in keeping battery topped off with distilled water. c.4A for 10 hours. replace assembly. 2. If the battery shows the following defects. Checking a. BREAKER b. Battery CAUTION: The silicon rectifier can be damaged if subjected t o overcharging. f. On occasion. If the motorcycle is not t o be used for a long time. Filling with water or sulfuric acid containing impurities. If the bottoms of the cells are filled with corrosive material falling off the plates. lightweight grease must be applied t o the weight pivot pins. Freezing. Battery being l e f t discharged. Improper charging voltage or current on new battery. Both weights must pivot smoothly or ignition advance will not occur a t the proper rpm. a. e. Ignition Circuit Diagram 2) No gassing occurs in any cell ENGINE STOP 3) The battery requires a charging voltage of MA" SWITCH more than regulating voltage in order t o supply a current o f 1. 1 2 V 14AH c. as required) E. .28 Quantity: 81Occ Initial charging current 1. (new battery) 3.. Over-charging with heavy charge. Recharge the battery before reinstallation.4 amp for 10 hours Recharging current 10 hours (or until specific gravity reaches 1. Battery 1. dry place. Recharge the battery periodically. Store the battery in a cool.28) Refill fluid Distilled water (to maximum level line) Refill period Check once per month (or more often.

a. d. Check the operation of the point cam on the shaft. proceed with individual component tests until the problem is found. IGNITION COIL. I t must rotate smoothly. Warm up engine thoroughly so that all electrical components are a t operating temperature. c. Examine point cam surface. Ignition Coil 1. ‘ORANGE * c. Connect fully charged battery to tester. Remove fuel tank and disconnect ignition coil from wire harness and spark plug. (Test a t various rpm‘s between idle and red line. 1. Direct current resistance test. the engine ignition system can be considered good._ _ RESISTANCE VALUE __ SPARK PLUG ’ 3. Use a pocket tester or equivalent ohmmeter t o determine resistance and continuity of primary and secondary coil windings. PRIMARY COIL _ . Start engine and increase spark gap until misfire occurs.b. Coil spark gap test. 2.24 in. C. I f the ignition system will fire across a sufficient gap.24 in. Connect Electro Tester as shown. Turn on spark gap switch and increase gap until misfire occurs.) | SECONDARY COIL RESISTANCE VALU IGNITION COIL I . Spark Gap Test ELECTRO-TESTER The entire ignition system can be checked for misfire and weak spark using the ElectroTester.) I 2. b. Stop engine and connect tester as shown. I f not. If surface is pitted or worn.) I Minimum spark gap: 6mm (0. Minimum spark gap: 6mm (0. the governor assembly must be replaced. D.

0K ohms ± 20% at 20°C (68°F) Insulation test. 1. note reading on "pF" scale. Condenser Test If the contact points show excessive wear. I t is actually economical t o install new plugs often since it will tend to keep theengine in good condition and prevent excessive fuel consumption. A t each periodic inspection. another may be ridden for hours a t high speed. I I Spark plug type: N-7Y (Champion) or BP-7ES (NGK) Spark plug gap: 0. 3. tail light. 1. Calibrate capacity scale.8mm I (0. always check battery voltage before proceeding further.0 ohms ± 10% at 20°C (68°F) Secondary coil resistance 11.031") 2 O N D E N S E R d &BATTERY 6-5 LIGHTING AND SIGNAL SYSTEMS A.22pF 2. Connect tester Instruct the rider to: c. check the condenser. Best condition: When the porcelain around the center electrode is a light tan color. tail light. INSULATION TEST.000 or more). I I f the electrodes and porcelain are black and somewhat oily. 6 . a. If none of the above operates. B. See section . How To "Read" A Spark Plug (Condition) 1. and flasher light. or a t least 2. or the spark is weak (but the ignition coil is in good condition).000 miles). Lighting Tests and Checks CAUTION: After this measurement. the condenser should be discharged by shorting the positive lead wire t o the condenser case. Recommend a hot. E. b. Condenser capacity: 0. One machine may be ridden only in urban areas a t low speeds.I able ones determined by the color and condition of the bad plugs. and flasher light. Inspection b. neutral light. Resistance reading should be 3M ohms.4 SPARK PLUG The life of a spark plug and its discoloring vary according to the habits of the rider. I f the porcelain is burned or glazed white and/or the electrodes are partially burned away. replace the plug with a colder type for high speed riding. stop light. I f less. Be sure to use the proper reach plug as a replacement t o avoid overheating. Inspect and clean the spark plug every 3. Low battery voltage indicates either a faulty battery.7~0. low battery water. Capacity test (use Electro Tester). stop light. m A. fouling or piston damage. replace. Standard values: Primary coil resistance: 4. The battery provides power for operation of the horn. Confirm what the present plugs indicate by asking the rider how long and how fast he rides. Meter needle will deflect and return to center as condenser is charged.028~0. neutral light. replace burned or fouled plugs with suit- The battery provides power for operation of the horn.200km (2. replace the plug with a hotter type for low speed riding. or cold plug type accordingly. ± 10% 3. standard. or a defective charging system. Clean the electrodes of carbon and adjust the electrode gap. If The battery provides power for operation o f the horn. Connect ohmmeter as shown (ohms x 1. After needle stops. a.

2)Check for 12V on brown wire t o flasher relay. c. Check flasher self-canceling system. The reserve lighting system has two functions: (1) I t notifies the rider that one of the head lamp filaments i s inoperative. If oil pressure is correct.) b. Description: a. If light comes on. b. 6-2 Charging System. 2)Check for ground on black wire to light assembly. Check for 12V on brown wire t o each brake light switch (front brake' and rear brake switches). c. e. Right and left circuits do not work: 1)Check for 12V on brown/white wire t o flasher switch on left handlebar. Check for good grounding of horn (pink wire) when horn button is pressed. 3. Check for 12V on brown wire t o horn. The system is connected t o the headlight circuit only. Check for 12V on blue wire. 2) Check for ground on black wire to light assemb Iy. a. "HEAD" lNDICATOR HEADLIGHT CONDITION Normal I High beam faulty Low beam faulty I *Comes on (very dim) Comes on Comes on RESERVE LIGHTING FUNCTION 1 Low beam comes on High beam comes on at low brilliance II . check for proper oil pressure. c. Brake light does not work: b. Replace any "open" fuses. Connect oil pressure switch (black/red wire) t o ground. 6. 3) Replace flasher relay. (Refer t o flasher self-canceling system. replace oil pressure switch. Check for ground on black wire t o tail/brake light assembly. d. There are individual fuses for various circuits (see complete Circuit Diagram). Check bulb. 2. 1. Right circuit: 1) Check for 12V on dark green wire t o light. c. Replace neutral switch. Check for 12V on sky blue wire t o neutral switch. Check bulb. b. B. and (2) it switches current from the inoperative filament t o the remaining functional filament. Check bulb. for checks of battery and charging system. Reserve Lighting System 4. L e f t circuit: 1) Check for 12V on dark brown wire t o light. 4) Replace flasher switch. The reserve lighting system unit is located under the fuel tank. Neutral light does not work: a. Check bulb. Tail light does not work: a. b. Horn does not work: a. Oil pressure light does not work: a. 5. Check for 12V on yellow wire t o brake light. Flasher light(s) do not work: 1. b. Also check fuse condition.

c. If the signal flashes only when the handle switch lever is turned t o L or R and it turns off immediately when the handle switch lever returns to center. proceed as follows: a. but the signal will function.. come inoperative. Generally. the following may be faulty: 1) Flasher canceling unit. replace the flasher canceling unit. 4) Handle switch light circuit. the speedometer sensor circuit is in good condition. Pull off the 6-pin connector from the flasher canceling unit. the signal may be cancelled manually. the sender or wire harness may be inoperative. If the tester needle swings back and forth. . .L (left). b. a t high speed. Pull off the 6-pin connector from the flasher canceling unit. 3) Lighting circuit. the canceling determination is a combination of both time and distance. . 2. whichever i s greater. . .I f the signal operates normally in L. . . The switch lever will return t o the "OFF" position after being pushed t o L o r R . and R (right).O ohms Flasher switch OFF. . 3. four times between 0 and -. FLASHER LIGHTS I 1 I 1) Flasher unit. If (1) through (4) are in good condition. Turn the speedometer shaft. the following are in good condition: C. Operation: The handle switch has three positions: -. check the handle switch circuit and wire harness. Description: The self-canceling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes. R. 2) Bulb. If not. If no defect i s found with the above three check-ups and the flasher canceling system is still inoperative. replace the flasher canceling unit. and connect a tester (ohms x 100 range) across the white/green and the black lead wires on the wire harness side. CANCELLING UNIT 4. Pull off the 6-pin connector from the flasher canceling unit. Flasher switch L or R I If the tester needle does not swing as indicated above. 3) Speedometer sensor circuit. and OFF.inf . the function is determined by distance. . and operate the handle switch. the signal will cancel after either10 seconds. it is determined by time. 2) Handle switch reset circuit. By pushing the lever in. Inspection: If the flasher self-canceling system should be. d. Check if there is continuity between the yellow/red lead wire on the wire harness side and the chassis. or 130 meters (142 yards). especially when changing speeds. . e. Self-Canceling Flasher System 1. A t very low speed. Circuit diagram. A t low speed. OFF.

I HEADLIGHT DOES NOT FUNCTION I INDICATOR LIGHT DOES NOT LIGHT WHEN LOW BEAM COMES ON-HIGH BEAM IS Reserve Unit Indicator Light and/or Wiring is Defective NOT FUNCTION I "HEAD" INDICATOR BULB DOES NOT GLOW 1 Voltage on "LG" Wire to Reserve Headlight Ground . .