Chapter 6, ELECTRICAL

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3. Main switch

4. Main fuse (20 amp)
5. Battery (12V 14 AH)
6. Starter motor
7. Starter relay
8. Starter switch
9. Ignition fuse (10 amp)
10. Engine Stop switch
11. Starting circuit cut-off relay
12. Clutch switch
13. Sidestand relay
14. Sidestand switch
23 Neutral switch

B. Starting circuit operation

The starting circuit on this model consists of the starter motor, starter relay, and the starting/Circuit cut-off relay. If the engine stop switch and the main switch are both on, the starter motor can operate only if:

a. The transmission is in neutral (the

or if

b. The clutch lever is pulled to the handlebar (the clutch switch is on) and the sidestand is up (the sidestand switch is on.)

The starting-circuit cut-off relay prevents the starter from operating when neither of these conditions has been met. In this instance, the starting-circuit cut-off relay is off so current cannot reach the starter motor.

When one or both of the above conditions have been met, however, the starting-circuit cut-off relay is on, and the engine can be started by pressing the starter switch.

When the transmission ii in neutral.

When the clutch lever on the handlebar is pulled and the side stand is up.

1. Main fuse
2. To main switch
3. To computer monitor
4. From sidestand relay
5. From engine stop switch
6. From neutral light
7. Starting-circuit- cut-off relay
8. Neutral switch
9. Clutch switch
10. Sidestand switch
11. Starter switch
12. Starter motor
13. Starter relay
14. Battery
15. From side stand relay

C. Starting-circuit cut-off relay inspection

1. Open the seat, and remove the fuel tank.

2. Remove the starting-circuit cut-off relay from the frame, and disconnect the connector.

1. Starting circuit cut-off relay

3. Check the resistance of the relay coil windings with the pocket tester. If the resistance is not within specification, replace the relay

1. Starting-circuit cut-off relay

4. Check the relay function with a 12 volt battery and the pocket tester. Connect the leads as shown in the illustration. If the resistance readings do not equal those shown in the illustration, replace the relay.

1. When the battery is connected
2. When the battery is disconnected 3.12 volt battery

5. Check the diode in the starting circuit cut-off relay with the pocket tester as shown in the illustration. Replace the relay if the diode is damaged.

NOTE:

Only the Yamaha Pocket Tester will give a 9.5Ω reading when testing continuity. The particular characteristics of other testers will very the continuity test readings.

1. Starting-circuit cut-off relay

D. Starter Motor

1. Removal (see ENGINE OVERHAUL)

2. Inspection and repair

a. Check the outer surface of the commutator. If its surface is dirty, clean with # 600 grit sand paper.

b. The mica insulation between commutator segments should be 0.4 — 0.8 mm (0.02 "- 0.03 in) below the segment level. If not, scrape to proper limits with appropriately shaped tool. (A hack saw blade can be ground to fit.)

NOTE:

Mica insulation of commutator must be undercut to ensure proper operation of commutator.

c. The starter's armature coil should be checked with an ohm meter for insulation breakdown (shorting to each other or to ground) and for continuity. Reference figure is given below.

Coil resistance: Armature coil: 0.014H at 20°C (68°F)

Continuity check

Insulation check

d. Check the front and rear cover bearings for damage. If damaged, the starter assembly must be replaced.

e. Check brush length. Replace brush if at, or near, limits.

Minimum brush length: 8.5 mm (0.33 in)

f. Check brush spring pressure. Compare it with a new spring. Replace the old spring if it is weak.

E. Starter Relay Switch

1. Inspection

a. Disconnect starter cable at the relay.

b. Connect pocket tester leads to the relay terminals (ohms x 1 scale).

c. Turn ignition to "ON" position, engine stop switch to "RUN" and change lever to "NEUTRAL".

d. Push the starter button. The relay should click once and the scale should read zero if it does not read zero, the relay must be replaced.

1, Battery load wire l+l
2. Starter motor lead wire

e. If the relay does not click, check the wires from the starter button and from the battery (red/white, blue/white). Turn the ignition off. Use (ohms x 1) scale on tester. The resistance between these wires should be no more than 3.5 ohms. If there is more resistance, the relay should be replaced.

Charging System

Model(s)

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1. AC Generator

2. Rectifier/Regulator
3. Main Switch
4. Main Fuse
5. Battery

B. A.C. Generator

1. Checking method.

a. Connect D.C. voltmeter to the battery terminals.

b. Start engine.

c. Accelerate engine to approximately 2,000. r/min or more and check generated voltage.

Generated voltage: 14.5 ± 0.3V

d. If the indicated voltage cannot be reached, then perform the tests in step 2.

CAUTION:

Never disconnect wires from the battery while the generator is in operation. If the battery is disconnected, the voltage across the generator terminals will increase, damaging the semiconductors.

2. Resistance test of field coil and stator coil.

Check the resistance between terminals. If resistance is out of specification, coil is broken. Check the coil connections. If the coil connections are good, then the coil is broken inside and it should be replaced.

Field coil resistance: (Green-Brown) 4.0Ω ± 10% at 20°C(68°F)

Armature coil resistance: (White-White) 0.46Ω ± 10% at 20°C(68°F)

1. Brown 2. Green

1. White

C. Voltage Regulator

The IC Voltage Regulator is a small and, normally, very reliable component. Due to its construction, it is lightweight and free from the wear and misadjustment associated with mechanical voltage regulators. If the following inspection reveals that the regulator is faulty, it cannot be adjusted and must be replaced.

1. Checking IC Voltage Regulator

a. Remove the seat.

b. Remove the left side cover.

c. Measure the specific gravity of the battery fluid. If it is less than 1.260, remove the battery and recharge until it is more than 1.260. {See page 6-23 for charging procedures)

d. Check the battery terminals and couplers for looseness.

e. Connect two Yamaha pocket testers to the regulator coupler as illustrated.

1. Black
2. Green
3. Brown

CAUTION:

Be careful not to let the tester leads short circuit when connecting them to the regulator snap connector leads.

f. Turn the main switch on. Make sure that V₂ is less than 1.8V.

NOTE:

Do not turn on lights or signals.

g. Make sure that V₂ gradually increases up to 9 ~ 11V when the engine is started and its revolutions go up.

1. Voltage

2. Approx. 2,000 r/min

3. Engine revolutions

h. Make sure that V₁ maintains the level of 14.2 ~ 14.8V even when engine revolutions increase.

i. If these levels are not maintained, the regulator is defective and must be replaced.

2. Checking the silicon rectifier

a. Check the silicon rectifier as specified using the Yamaha pocket tester.

1. Rectifier
2. Red (d)
3. Brown
4. IC Regulator
5. Green
6. Black (e)
7. White (c)
8. White (b)
9. While (a)

Checking element	Pocket tester connecting point		Good	Replace (element shorted)	Replace (element opened)
Checking element	(+) (red)	(black)	Good	Replace (element shorted)	Replace (element opened)
D₁	d	a	o	o	x
D₁	a	d	X	o	X
D₂	d	b	o	0	X
D₂	b	d	X	0	X
D₃	d	c	o	o	X
D₃	c	d	X	o	X
D₄	a	e	0	o	X
D₄	e	a	X	0	X
D₅	b	e	0	o	X
D₅	e	b	X	o	X
D₆	c	e	0	o	X
D₆	e	c	X	o	X

O : Continuity

x : Discontinuity (∞)

b. Even if only one of the elements is broken, replace the entire assembly.

CAUTION:

The silicon rectifier can be damaged if subjected to overcharging. Special care should be taken to avoid a short circuit and/or incorrect connection of the positive and negative leads at the battery. Never connect the rectifier directly to the battery to make a continuity check.

Ignition System

Model(s)

xjcdadmin Sun, 05/30/2010 - 09:23

3. Main switch

4. Main fuse (20 amp)
5. Battery (12V 14 AH)
9. Ignition fuse (10 amp)
10. Engine Stop switch
11. Starting circuit cut-off relay
12. Clutch switch
13. Sidestand relay
14. Sidestand switch
15. Ignitor unit
16. Ignition coil
17 Spark plug
18. Pickup coil
23 Neutral switch

B. Description

This model is equipped with a battery operated, fully transistorized, breakerless ignition system. By using magnetic pickup coils, the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition timing. The TCI (Transistor Control Ignition) unit incorporates an automatic advance circuit controlled by signals generated by the pickup coil. This adds to the dependability of the system by eliminating the mechanic advancer. This TCI system consists of two units; a pickup unit and an ignitor unit.

NOTE:

The ignition circuit can be operated only when the sidestand is up (the sidestand switch is on) or the transmission is in neutral.

C. Operation

The TCI functions to the same principle as a conventional DC ignition system with the exception of using magnetic pickup coils and a transistor control box (TCI) in place of contact breaker points.

1. Pickup unit

The pickup unit consists of two pickup coils and a flywheel mounted onto the crankshaft. When the projection on the flywheel passes a pickup coil, a signal is generated and transmitted to the ignitor unit. The width of the projection on the flywheel determines the ignition ad-vance.

2. Ignitor unit

This unit controls when form, duty control, switching, electronic ignition advance, etc. The duty control circuit reduces electrical consumption by controlling the duration of the primary ignition current.

The ignitor unit also has a protective circuit for the ignition coil. If the igni tion switch is on and the crankshaft is not turning, the protectice circuit inter-

rupts the current flow to the primary coil after a few seconds. When the crankshaft is turning, however, the ignitor unit sends current to the primary coil.

3. Sidestand relay

The sidestand relay operates by shorting the TCI control current. When the side-stand is down, the sidestand relay is closed, and the TCI control current is grounded through the sidestand relay. Thus, the engine will not run with the sidestand down unless the transmission is in neutral.

1. TCI control current from TCI unit
2. Sidestand relay
3. From engine stop switch
4. From clutch switch
5. Neutral switch
6. Sidestand switch
7. From starting-circuit cut-off relay
8. When the sidestand is up.
9. When the transmission is in neutral and the sidestand is down.

D. Sidestand relay

1. Open the seat, and remove the fuel tank.

2. Remove the sidestand relay from the frame, and disconnect the connector.

1. Sidestand relay

3. Check the resistance of the relay coil windings with the pocket tester. If the resistance is not within specification, replace the relay.

1. Sidestand relay

4. Check the relay contact breaker points with the pocket tester and a 12 volt battery. Connect the leads as shown in the illustration. If the resistance readings do not equal those shown in the illustration, replace the relay.

1. When the battery is connected.
2. When the battery is disconnected.
3. 12 volts battery

E. Ignition Coil

1. Coil spark gap test.

a. Remove the fuel tank and disconnect the ignition coil from wire harness and spark plugs.

b. Connect the Electro Tester as shown.

1. Ignition coil
2. Battery

c. Connect fully charged battery to tester.

d. Turn on spark gap switch and the increase gap to maximum unless misfire occurs first.

Minimum spark gap: 6 mm (0.24 in)

2. Direct current resistance test. Use a pocket tester or equivalent ohmmeterto determine resistance and continuity of primary and secondary coil windings.

Standard value:
Primary coil resistance: 2.5Ω ± 10% at 20°C(68°F)
Secondary coil resistance: 11KΩ ±20% at 20°C(68°F)

Primary coil check

1. Ignition coil

Secondary coil check

1, Ignition coil

F. Spark Plug

The life of a spark plug and its discoloring vary according to the habits of the rider. At each periodic inspection, replace burned or fouled plugs with new ones of the specified type. It is actually economical to install new plugs often since it will tend to keep the engine in good condition and prevent excessive fuel consumption.

1. Inspection

a. Inspect and clean at the specified intervals and replace as required.

b. Clean the electrodes of carbon and adjust the electrode gap to the specification.

2. Installation

Be sure to use the proper reach, type and electrode gap plug(s) as a replacement to avoid overheating, fouling or piston damage.

Type: BPR7ES (NGK) or W22EPR-U
Electrode gap: 0.7- 0.8 mm (0.028-0.031 in)
Tightening torque: 20 Nm (2.0m-kg, 14.5 ft-lb)

G. Troubleshooting/Inspection

1. The entire ignition system can be checked for misfire and weak spark using the Electro Tester. If the ignition system will fire across a sufficient gap, the entire ignition system can be considered good. If not, proceed with individual component tests until the problem is fround.

a. Warm up engine thoroughly so that all electrical components are at operating temperature.

b. Stop the engine and connect the tester as shown.

1. Electro tester

2. Spark plug wire

c. Start the engine and increase the spark gap until misfire occurs. (Test at various r/min between idle and red line.)

Minimum spark gap: 6 mm (0.24 in)

CAUTION:

Do not run engine in neutral above 6,000 r/min for more than 1 or 2 seconds.

2. If the ignition system should become inoperative, the following troubleshooting aids will be useful.

Check entire ignition for connections	Poor connection >>>	Correct
OK
Check battery for voltage and specific gravity	Low voltage & specific gravity >>>	Recharge battery
OK
Check fuse and fuse connections	Weak connection or open circuit >>>	Correct connection or replace fuse
OK
Check resistance of ignition coil (primary and secondary) Primary: 2.5Ω± 10% at 20C(68°F) Secondary: 11KΩ± 20% at 20°C(68°F)	If other than specified >>>	Replace ignition coil
OK		.
Check pick-up coils for resistance Pick-up coil: 700Ω±20% at 20°C (68°F)	If other than specified >>>	Replace pick-up coil assembly
OK
TCI unit is faulty, replace unit

Lighting System

Model(s)

xjcdadmin Sun, 05/30/2010 - 09:23

3. Main switch

4. Main fuse
5. Battery
32 Meter light (3.4w x 2)
33. Headlight fuse (10A)
34 Brake/tail light (27/8W)
35. High beam indicator (3.4W)
36. Headlight dimmer switch
37. Headlight (60/55W)

B. Lighting Tests and Checks

The battery provides power for operation of the headlight, taillight, and meter lights. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery water, or a defective charging system. See "CHARGING SYSTEM" for checks of battery and charging system. Also check fuse condition. Replace any "open" fuses. There are individual fuses for various circuits (see complete Circuit Diagram).

NOTE:

Check the headlight bulb first before performing the following check.

1. Headlight check

NOTE:

When the main switch is turned to "ON", the headlight and meter lights come on automatically and the lights stay on until the ignition switch is turned to "OFF" even if the engine stalls.

Headlight does not come on when ignition switch is turned on

Check the headlight butb.	Faulty
OK
Check the continuity of dimmer switch (L/B-Y, L/B-G wires).	Faulty	Replace the switch \|
OK
Check the continuity of starter switch (R/Y- L/Bwire).	Faulty	Replace the switch \|
OK
Check ihe headlight fuse.	Faulty	Replace the fuse.
OK
Check the continuity of main twitch (R-Brwire).	Faulty	Replace the switch.
OK
Check the main fuse.	Faulty	Replace the fuse.
OK
Check battery voltage.	Low	Charge or replace.
OK
Faulty grounding or faulty connection of headlight switch.

2. Taillight does not work:

a. Check bulb.

b. Check for 12V on blue wire.

c. Check for ground on black wire to tail/brake light.

Signals

Model(s)

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3. Main switch
4. Main fuse (20A)
5. Battery (12V 14AH)
19. Fuse (SIGNAL 10A}
20. Front brake switch
21. Rear brake switch
22. Neutral light (3.4W)
23. Neutral switch
24. Flasher relay
25. "TURN" switch
26. Flasher light (27VV x 4)
27. Cancelling unit
28. Horn
29. Horn switch
30. Speedometer
31. Reed switch
34. Brake/tail light (27/8VV)
40. Tachometer
41. Flasher indicator lights (3.4W)

B- Signal System Tests and Checks
The battery provides power for operation of the horn, brakelight, indicator lights and flasher light. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery water, or a defective charging system. See "CHARGING SYSTEM" for checks of battery and charging system. Also check fuse condition. Replace any "open" fuses. There are individual fuses for various circuits (see complete Circuit Diagram).

1. Horn does not work:
a. Check for 12V on brown wire to horn.
b. Check for good grounding of horn (pink wire) when horn button is pressed.

2. Brake light does not work:
a. Check bulb.
b. Check for 12V on yellow wire to brake light.
c. Check for 12V on brown wire to each brake light switch (front brake and rear brake switches).

3. Flasher light(s) do not work:
a. Check bulb.
b. Right circuit:
1) Check for 12V on dark green wire to light.
2) Check for ground on black wire to light assembly.
c. Left circuit:
1) Check for 12V on dark brown wire to light.
2) Check for ground on black wire to light assembly.

d. Right and left circuits do not work:
1) Check for 12V on brown/white wire to flasher switch on left handlebar.
2) Check for 12V on brown wire to flasher relay.
3) Replace flasher relay.
4) Replace flasher switch.
e. Check flasher self-cancelling system. (Refer to flasher self-cancelling system.)

4. Neutral light does not work:
a. Check bulb.
b. Check for 12V on sky blue wire to neutral switch.
c. Replace neutral switch.

6. Oil level warning light does not work:
a. Connect oil level switch (black/red wire) to ground. If light comes on, check for proper oil level.
b. If oil level is correct, replace oil level switch.

C. Self-Cancelling Flasher System

1. Description:

The self-cancelling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes. Generally, the signal will cancel after either 10 seconds, or 150 meters (490 feet), whichever is greater. At very low speed, the function is determined by distance; at high speed, especially when changing speeds the cancelling determination is a combination of both times and distance.

2. Operation:

The handlebar switch has three positions: L (left), OFF, and R (right). The switch lever will return to the "OFF" position after being pushed to L or R, but the signal will function. By pushing the lever in, the signal may be cancelled manually.

3. Inspection

If the flasher self-cancelling system should become inoperative, proceed as follows:

a. Pull of the 6-pin connector from the flasher cancelling unit, and operate the handlebar switch, if the signal operates normally in L, R, and OFF, the following are in good condition.

1) Flasher unit
2) Bulb
3) Lighting circuit
4) Handlebar switch light circuit

If (1) through (4) are in good condition, the following may be faulty:

1) Flasher cancelling unit.
2) Handlebar switch reset circuit.
3) Speedometer sensor circuit.

b. Pull off the 6-pin connector from the flasher cancelling unit, and connect a tester (ohms x 100 range) across the white/green and the black lead wires on the wire harness side. Turn the speedometer shaft. If the tester needle swing back and forth between 0 and oo, the speedometer sensor circuit is in good condition. If not, the sensor to wire harness may be inoperative.

c. Pull the 6-pin connector from the flasher cancelling unit. Check if there is continuity between the yellow/red lead wire on the wire harness side and the chassis.

Flasher switch OFF: ∞ (infinite)
Flasher switch L or R: 0 ohms

If the tester needle does not swing as indicated above, check the handlebar switch circuit and wire harness.

d. If no defect is found with the above three check-ups and the flasher cancelling system is still inoperative, replace the flasher cancelling unit.

e. If the signal flashes only when the handlebar switch lever is turned to L or R and it turns off immediately when the handlebar switch lever returns to center, replace the flasher cancelling unit.

Battery

Model(s)