Charging System

CIRCUIT DIAGRAM

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CD CDI Magneto COLOR CODE

@ Rectifier/Regulator B Black

(5) Battery Br Brown

L Blue

0 Orange

R Red

Sb Skyblue

W White

Y Yellow

B/W Black/White

B/Y Black/Yellow

G/L Green/Blue

G/W Green/White

L/W Blue/White

R/W Red/White

W/B White/Black

W/G White/Green

Y/B Yellow/Black

TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

Procedure

Check;

1. Fuse

2. Battery

3. Charging voltage

4. Charging coil resistance

5. Wiring connection (Entire charging system)

NOTE:

•Remove the following parts before troubleshooting. 1) Seat

•Use the following special tool(s) in this troubleshooting.

Inductive tachometer: P/N. YU-08036

Pocket tester: P/N. YU-03112

Pocket tester: P/N. YU-03112

1. Fuse

•Check the fuse condition. Refer to the "FUSE INSPECTION" section in the CHAPTER 3.

CORRECT

2. Battery

• Check the battery condition. Refer to the "BATTERY INSPECTION" section in the CHAPTER 3.

^CORRECT

3. Charging voltage

•Connect the Inductive tachometer to the spark plug lead.

INCORRECT

INCORRECT

Fuse is faulty, replace it.

•Refill battery fluid. •Clean battery terminals. •Recharge or replace battery.

• Connect the Pocket tester (DC20V) to the battery.

Tester ( + ) lead-»Battery positive terminal

Tester (-) lead-»Battery negative terminal

•Turn the "LIGHT" (Dimmer) switch to "OFF"

position. • Start the engine.

•Accelerate the engine to specifications and check the charging voltage.

Charging voltage:

14-15V at 5,000 r/min

OUT OF SPECIFICATION

4. Charging coil resistance

• Disconnect the CDI magneto leads from the wireharness.

• Connect the Pocket tester (Q x 1) to the charging coil leads.

Charging coil (1): Tester ( + ) lead-»White lead (f) Tester (-) lead-»White lead (2)

Charging coil (2): Tester ( + ) lead-»White lead © Tester (-) lead-»White lead (3)

MEETS SPECIFICATION

Charging system is good.

•Check the charging coils for specificated resistance.

OUT OF SPECIFICATION

Charging coil resistance: 0.70-0.86« at 20°C (68°F) (White-White)

OUT OF SPECIFICATION

Charging coils are faulty, replace them.

Charging coils are faulty, replace them.

BOTH RESISTANCES MEET SPECIFICATIONS

5. Wiring connection

POOR CONNECTION

• Check the entire charging system for connections. Refer to the "WIRING DIAGRAM" section.

*

CORRECT

Rectifire/Regulator is faulty, replace it.

IGNITION SYSTEM

CIRCUIT DIAGRAM

SCDI magneto COLOR CODE

CDI unit B Black

(D Ignition coil Br Brown

© Main switch L Blue

© "ENGINE STOP" switch 0 Orange

R Red

Sb Skyblue

W White

Y Yellow

B/W Black/White

B/Y Black/Yellow

G/L Green/Blue

G/W Green/White

L/W Blue/White

R/W Red/White

W/B White/Black

W/G White/Green

Y/B Yellow/Black

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