Batterycharging System

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SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING

BATTERY

CHARGING SYSTEM INSPECTION 16-7 ALTERNATOR CHARGING COIL 16-8

REGULATOR/RECTIFIER 16-9

SERVICE INFORMATION

GENERAL

A WARNING

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging.

The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may causc severe burns. Wear protective clothing and a facc shield.

- If electrolyte gets on your skin, flush with water.

- If electrolyte gets in your eyes, flush with water tor at least 15 minutes and call a physician immediately. Electrolyte is poisonous.

- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician immediately.

Always turn off the ignition switch before disconnecting any clcctricol component.

Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is turned to "ON" and current is present.

For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum scrvicc life, charge the stored battery every two weeks.

For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. The maintenance free battery must be replaced when it reaches the end of its service life.

The battery can be damaged of overcharged or undercharged, or of left to discharge for long period. These same conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years.

Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly.

Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and taillight on for long periods of time without riding the motorcycle.

• The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent sulfation from occurring.

• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 16-3).

• For battery charging, do not exceed the charging current and time specified on the battery. Use of excessive current or charging time may domogc the battery.

BATTERY TESTING

Refer to the instruction of the Operation Manual for the recommended battery tester. The recommended battery tester puts a "load" on the battery so that the actual battery condition of the load can be measured.

Recommended battery tester BM210-AH (U.S.A. only), BM-210 or BATTERY MATE or equivalent SPECIFICATIONS

ITEM

SPECIFICATIONS

Battery

Capacity

12V- 8.6 Ah

Current leakage

2.0 mA max.

Voltage (20"C/68'F)

Fully charged

13.0- 13.2 V

Needs charging

Below 12.3 V

Charging current

Normal

0 .9 A/5 - 10 h

Quick

4.5 A/0.5 h

Alternator

Capacity

0.433 kW/5,000 rpm

Charging coil resistance (20°C/68QF)

0.1- 1.0 Q

TROUBLESHOOTING

BATTERY IS DAMAGED OR WEAK

Remove the battery (page 16-5). Check the battery condition using the recommended battery tester.

RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent

Incorrect

Faulty battery.

Correct

Install the battery (page 16-b).

Check the battery current leakage (leak test;

Incorrect

Disconnect the regulator/rectifier connector and recheck the battery current leakage.

Correct

Correct

Incorrect

• Shorted wire harness.

• Faulty ignition switch.

Faulty regulator/rectifier.

Check the alternator charging coil (page 16-8). STANDARD: 0.1 - 1.0 £1 (20;C/68'F)

Incorrect

Faulty charging coil.

Correct

Measure and record the battery voltage using a digital multimeter (page 16-5). Start the engine.

Measure the charging voltage (page 16-8). Compare the measurement to result of the following calculation.

STANDARD:

Measured battery voltage < Measured charging voltage < 15.5 V

Correct

Faulty battery.

Incorrect

Check the voltage and resistance at the rcgula tor/rectifier connector (page 16-9).

Incorrect

Open circuit in related wire.

Loose or poor contacts of related terminal.

Shorted wire harness.

Correct

Correct

Open circuit in related wire.

Loose or poor contacts of related terminal.

Shorted wire harness.

• Faulty regulator/rectifier.

BATTERY

Always turn the ignition switch to "OFF" before removing the battery.

REMOVAL/INSTALLATION

Remove the ECM (page 5-85).

Open the battery case cover by releasing the two locking clips.

Disconnect the negative cable and then the positive cable, and remove the battery.

Install the battery in the reverse order of removal with the proper wiring as shown.

Connect th* posi- After installing the battery, coot the terminals with tive lerminai first clean grease. and then the negative cable.

BATTERY

VOLTAGE INSPECTION

Measure the battery voltage using a digital multimeter.

VOLTAGE: Fully charged: 13.0- 13.2V Under charged: Below 12.3V

TOOL:

Digital multimeter Commercially available

BATTERY TESTING

BATTERY

Always clear the work area of flammable materials such as gasoline, brake fluid, electrolyte, or cloth towels when operating the tester. The heat generated by the tester may cause a fire.

Remove the battery (see above).

Securely connect the tester's positive (0 cable first, then connect the negative (-) cable.

TOOL:

Battery tester

BM-210-AH (U.S.A. only), BM210 or BATTERY MATE or equivalent

BATTERY

BATTERY

BLACK

CASE COVER

LOCKING CLIPS

CASE COVER

LOCKING CLIPS

BATTERY

TERMINAL

BATTERY

TERMINAL

For accurate test Sel the temperature switch to "HIGH" or "LOW" results, be sure depending on the ambient temperature.

the tester's cables and clamps aie in good working condition and that a secure connection can be mode at the battery.

0)0)0 0 o

l_J

LJ

HIGH:

15 *C (60 T) or higher

LOW:

15 °C <60 *F) or lower

ror the first check, DO NOT charge the battery before testing; test it in an "as is " condition.

Push in the appropriate test button for 3 seconds and read the condition of the battery on the meter.

To avoid damaging the tester, only test batteries with an amperage rating of less than 30 Ah.

Tester damage can result from overheating when:

- The test button is pushed in for more than 3 seconds.

- The tester is used without being allowed to cool for at least 1 minute when testing more than one bat tery.

- More than 10 consecutive tests are performed without allowing at least a 30 minute cool-down period.

The result of a test on the meter scale is relative to the

TEST BUTTONS

I

y'00000'© O °

amp. hour rating of the battery. ANY BATTERY READING IN THE GREEN ZONE IS OK. Batteries should only be charged if they register in the YELLOW or RED

zone.

YELLOW

BATTERY CHARGING

Remove the battery (page 16-5).

• Clean the battery terminals and position the battery as far away from the charger as the leads will permit.

• Do not place batteries below the charger-gases from the battery may corrode and damage the charger.

• Do not place batteries on top of the charger. Be sure the air vents are not blocked.

TOOL:

Christie battery charger

1.Turn the Power Switch to the OFF position.

2. Set the battery Amp. Hr. Sclcctor Switch for the size of the battery being charged.

3. Set the Timer to the position indicated by the Honda Battery Tester; RFD-3, RED-2, or YELLOW 1.

If you are charging a new battery, set the switch to the NEW BATT position.

4. Attach the clamps to the battery terminals; RED to Positive, BLACK to Negative.

Connect the battery cables only when the Power Switch is OFF.

BATTERY AMP HR. SELECTOR SWITCH

5.5 to 9.0 3.5 to 5.0 i 9.5 to 16.0 0 to 0.3 .16.5 to 30

Set the appropriate amp. hour rating.

The charger will automatically switch ro the "TricK>9 " mode after the set charyiny time has ClODCCd.

5. Turn the Power Switch to the ON position.

6. When the timer reaches the "Trickle" position, the charging cycle is complete. Turn the Power Switch OFF and disconnect the clamps.

7. Let the battery cool for at least 10 minutes or until gassing subsides after charging.

8. Reset the battery using the Honda Battery Tester and recharge if necessary using the above steps.

CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE INSPECTION

Turn the ignition switch off and disconnect the negative battery cable from the battery. Connect the ammeter (+) probe to the ground cable and the ammeter <-) probe lo the battery (-) terminal. Willi the ignition switch off, check for current leakage.

• When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester.

• While measuring current, do nol lurn the ignition on. A sudden surge of current may blow out the fuse in the tester.

SPECIFIED CURRENT LEAKAGE: 2.0 mA max.

If current leakage exceeds the specified value, a shorted circuit is likely.

Locate the short by disconnecting connections one by one and measuring the current.

TIMER

Trickle

NEW BATT

CHARGING VOLTAGE INSPECTION

Be sure the battery is in good condition before performing this test.

Do no: disconnect the battery or any cable in the charging system without first switching off the ignition switch, raiiure to follow this precaution con damage the tester or electrical components.

Warm up the engine to normal operating temperature. Stop the engine, and connect the multimeter as shown.

• To prevent a short, make absolutely certain which are the positive and negative terminals or cable.

Restart the engine.

With the headlight turned to the high beam position, measure the voltage on the multimeter when the engine runs at 5,000 rpm.

Standard: Measured battery voltage (page 16-5) c Measured charging voltage (see above) < 15.5 V at 5,000 rpm

ALTERNATOR CHARGING COIL

It is not necessary INSPECTION

to remove the stator coii to Remove the left lower cowl (page 2-4).

make this test.

Disconnect the alternator 3P (White) connector.

Check the resistance between all three Yellow terminals.

Check for continuity between all three Yellow terminals and Ground. There should be no continuity.

If readings are far beyond the standard, or it any wire has continuity to ground, replace the alternator stator. Refer to section 10 for stator removal.

3P (WHITE) CONNECTOR

3P (WHITE) CONNECTOR

3P (WHITE) CONNECTOR

REGULATOR/RECTIFIER

SYSTEM INSPECTION

Disconnect the regulator/rectifier connectors, and check it for loose contact or corroded terminals.

6P (BLACK) CONNECTOR

6P (BLACK) CONNECTOR

It the regulated voltage reading (see page 16-6) is out of the specification, measure the voltage between connector terminals (wire harness side) as follows:

Item

Terminal

Specification

Battery charging line

Red/White (+) and ground (-)

Battery voltage should register

Charging coil line

(at 20"C/68T)

Ground line

Green and Continuity ground should exist

Position Regulator Bandit 600

If all components of the charging system are normal and there are no loose connections at the regulator/rcc tifier connectors, replace the regulator/rectifier unit.

REMOVAL/INSTALLATION

Disconnect the alternator 3P (White) connector. Disconnect the alternator 6P (Black) connector.

6P (BLACK) CONNECTOR

6P (BLACK) CONNECTOR

3P (WHITE) CONNECTOR

Remove the regulator/rectifier unit mounting bolts, regulator/rectifier and plate.

Install the regulator/rectifier unit in the reverse order of removal.

REGULATOR/RECTIFIER

PLAIE

REGULATOR/RECTIFIER

PLAIE

SYSTEM DIAGRAM

TNGINF STOP SWITCH IGNITION SWITCH _ I THROTTLE SENSOR

CLUTCH SWITCH

DIRECT IGNITION COIL

CAM PULSE GENERATOR

CLUTCH SWITCH

Cbr 250r All Meter Restarted

NEUTRAL SWITCH

BATTERY MAIN FUSE I FUSE BOX

ENGINE STOP RELAY

SPARK PLUGS

IGNITION PULSE GENERATOR

.rTTSv

NEUTRAL SWITCH

SIDE S I AND SWITCH

nfutrai SWITCH

SIDE STAND SWITCH

2P IGrMn)

To Tochomater tl-

CLUTCH SWITCH

LS

Bu/B

Nn 1

I

_

y

T

/

FNGWF STOP KfclAY

KJ.iWV J HI

To Bank Angle Scnaor ► To Engin« Stop Switch

MAIN ruse (A) 30A

PGM-n ruse 20A

To Ignrtion Switch

TP SENSOR

BATTERY -

ïCf.1 (Engine Contro1 Module!

I (Natural)

CAM Pill SF WMUhKAII.IK

IGNIIKM PULSfc GENERATOR

DIRECT IGNITON COIL

Lg: Light graan W: Whita Gr: Gray

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    How to remove rectifier mounting plate honda cbr?
    4 years ago

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