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14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
14 Battery Fuse
Regulator/Rectifier
CDI
Resistors
A.C. Generator
G Y W R
G/B
Y G
Resistor
A.C. Generator
Auto
Bystarter Regulator/
14
Headlight Switch
Rectifier
5
5W Battery
12V4AH
14-0
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGIKITY 50
SERVICE INFORMATION...................... 14-1 A.C. GENERATOR CHARGING COIL ...14-6
TROUBLESHOOTING ............................ 14-2 RESISTOR INSPECTION........................14-6
BATTERY................................................. 14-3 A.C. GENERATOR REMOVAL .............14-6
CHARGING SYSTEM ............................. 14-4 A.C. GENERATOR INATALLATION ...14-8
REGULATOR/RECTIFIER...................... 14-5
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and
eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and
get prompt medical attention
· The battery can be charged and discharged repeatedly. If a discharged battery is not used for a
long time, its service life will be shortened. Generally, the capacity of a battery will decrease
after it is used for 23 years. A capacity-decreased battery will resume its voltage after it is
recharged but its voltage decreases suddenly and then increases when a load is added.
· When a battery is overcharged, some symptoms can be found. If there is a short circuit inside
the battery, no voltage is produced on the battery terminals. If the rectifier won`t operate, the
voltage will become too high and shorten the battery service life.
· If a battery is not used for a long time, it will discharge by itself and should be recharged every 3
months.
· A new battery filled with electrolyte will generate voltage within a certain time and it should be
recharged when the capacity is insufficient. Recharging a new battery will prolong its service life.
· Inspect the charging system according to the sequence specified in the Troubleshooting.
· Do not disconnect and soon reconnect the power of any electrical equipment because the electronic
parts in the regulator/rectifier will be damaged. Turn off the ignition switch before operation.
· It is not necessary to check the MF battery electrolyte or fill with distilled water.
· Check the load of the whole charging system.
· Do not quick charge the battery. Quick charging should only be done in an emergency.
· Remove the battery from the motorcycle for charging.
· When replacing the battery, do not use a traditional battery.
· When charging, check the voltage with an voltmeter.
14-1
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
SPECIFICATIONS
Item Standard
Capacity/Model 12V-4AH
Voltage Fully charged 13.1V
Battery (20 ) Undercharged 12.3V
Charging current STD: 0.4A Quick: 4.0A
Charging time STD: 510hr Quick: 30min
Capacity 0.144KW/5000rpm
A.C. Generator Lighting coil resistance (20 ) YellowGreen 0.11.0
Charging coil resistance (20 ) WhiteGreen 0.21.2
Type Single-phase half-wave SCR
13.113.9V/5000rpm (Electric tester, tachometer)
Regulator/Rectifier Lighting
Limit voltage 13.1±0.5V
Charging 14.5±0.5V/5000rpm
Resistance (20 ) 5W12
Resistor
Resistance (20 ) 30W7.5
TORQUE VALUES
Pulser coil bolt 0.45~0.6kgf-m
Stator bolt 0.8~1.2kgf-m
Flywheel nut 3.5~4.5kgf-m
Cooling fan bolt 0.8~1.2kgf-m
SPECIAL TOOLS
Universal holder
Flywheel puller
TESTING INSTRUMENTS
Kowa electric tester
Sanwa electric tester
TROUBLESHOOTING
No power Intermittent power
· Dead battery · Loose battery cable connection
· Disconnected battery cable · Loose charging system connection
· Fuse burned out · Loose connection or short circuit in
· Faulty ignition switch lighting system
Low power Charging system failure
· Weak battery · Loose, broken or shorted wire or connector
· Loose battery connection · Faulty regulator/rectifier
· Charging system failure · Faulty A.C. generator
· Faulty regulator/rectifier
14-2
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGIKITY 50
Battery Cover
BATTERY
REMOVAL
Remove the battery cover screws on the floor
board.
Open the battery cover and remove the
battery by removing the bolt and band.
First disconnect the battery negative (-) cable
and then the positive (+) cable.
When disconnecting the battery positive
(+) cable, do not touch the frame with
tool; otherwise it will cause short circuit
and sparks to fire the fuel.
The installation sequence is the reverse of battery
removal.
First connect the positive (+) cable and the
negative (-) cable to avoid short circuit.
BATTERY VOLTAGE (OPEN CIRCUIT
VOLTAGE) INSPECTION
Remove the floor board.
Open the battery cover and disconnect the
battery cables.
Measure the voltage between the battery
terminals.
Fully charged : 13.1V
Undercharged : 12.3V max. negative (-) cable positive (+) cable
Battery charging inspection must be
performed with a voltmeter.
CHARGING
Connect the charger positive (+) cable to the
battery positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-) terminal.
· Keep flames and sparks away from a
charging battery.
· Turn power ON/OFF at the charger, not
at the battery terminals to prevent
sparks near the battery to avoid
explosion.
· Charge the battery according to the
t ifi d th b tt
· Quick charging should only be done in Red Power Lamp (Red)
an emergency.
· Measure the voltage 30 minutes after Black Charging Lamp (Green)
the battery is charged.
Charging current: Standard : 0.4A
Quick : 4A
Charging time : Standard : 510 hours
Quick : 30 minutes
After charging: Open circuit voltage: 12.8V min.
Note: The battery temperature should not
exceed 45 during charging.
14-3
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
Terminal
CHARGING SYSTEM
SHORT CIRCUIT TEST
Disconnect the ground wire from the battery
and connect an ammeter across the battery
negative (-) terminal and the ground wire.
Turn the ignition switch OFF and check for
short circuit.
Connect the electric tester positive (+)
terminal to ground wire and the tester
negative (-) terminal to the battery
negative (-) terminal.
If any abnormality is found, check the ignition Battery
switch and wire harness for short circuit .
(-) Terminal (+) Terminal
CURRENT TEST
This inspection must be performed with an
electric tester when the battery is fully
charged.
Warm up the engine for inspection.
Connect the electric tester across the battery
terminals. Disconnect the fuse and connect an
ammeter between the fuse terminals.
Attach a tachometer to the engine.
Start the engine and gradually increase the
engine speed to measure the limit voltage and
current.
Limit Voltage/Current: 1415V/0.5A max. fuse
(5000rpm max.) Headlight Wire Coupler
If the limit voltage is not within the specified
range, check the regulator/rectifier. ( 14-5)
LIGHTING SYSTEM LIMIT VOLTAGE
INSPECTION
Remove the handlebar front cover. ( 2-2)
Measure the voltage with the electric
tester in the AC range.
Limit Voltage: 1214V/ (5000rpm max.)
If the limit voltage is not within the specified
range, check the regulator/rectifier. ( 14-5)
Perform this test with a fully charged
battery.
14-4
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGIKITY 50
Regulator/Rectifier
REGULATOR/RECTIFIER
MAIN HARNESS CIRCUIT INSPECTION
Remove the front covers. ( 2-2)
Remove the regulator/rectifier 4P coupler and
check for continuity between the wire harness
terminals according to the following :
Item (Wire Color) Judgment
Between battery (red) Battery has
and engine ground voltage
Between ground (green) Continuity exists
and engine ground
Between lighting wire
(yellow) and engine
ground (Remove the A.C. generator
resistor coupler and auto stator has
bystarter coupler and resistance
turn the lighting switch
OFF for inspection)
Between charging coil A.C. generator
(white) and engine stator has
ground resistance
Red Yellow
REGULATOR/RECTIFIER INSPECTION
If the main harness terminals are normal,
check the regulator/rectifier coupler for loose
connection and measure the resistances
between the regulator/rectifier terminals.
· Do not touch the tester probes with
your finger because human body has
resistance.
· Use the following specified testers for
accurate testing. Use of an improper
tester in an improper range may give
false readings. White Green
- Kowa Electric Tester
- Sanwa Electric Tester
- Kowa Electric Tester TH-5H Probe
White Yellow Red Green
· Proper range for testing:
Probe(-)
- Use XK range for Sanwa Tester White 3K-50K
- Use X100 range for Kowa Tester Yellow 5K-100K
· If the dry battery in the tester is weak, Red
the readings will be incorrect. In this
case, check the dry battery. Green 5K-50K
· The Kowa tester readings are 100
times the actual values. Be careful
during testing.
Replace the regulator/rectifier if the readings
are not within the specifications in the table.
14-5
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
A.C. GENERATOR CHARGING Charging Coil Wire
COIL
The inspection of A.C. generator charging
coil can be made with the engine installed.
INSPECTION
Disconnect the A.C. generator 2P connector.
Measure the resistance between the A.C.
generator white wire and engine ground with
an electric tester.
Standard: 0.21.2(at 20 )
Replace the A.C. generator charging coil if
the reading is not within the specifications.
A.C. GENERATOR LIGHTING
COIL
The inspection of A.C. generator lighting
coil can be made with the engine installed.
INSPECTION
Disconnect the A.C. generator 2P connector.
Measure the resistance between the A.C.
generator yellow wire and engine ground
Lighting Coil Wire
with an electric tester.
Standard: 0.11.0 (20 )
Replace the A.C. generator lighting coil if the
reading is not within the specifications.
RESISTOR INSPECTION
Remove the front covers. ( 2-2)
Measure the resistance between the resistor
lead and engine ground.
Resistances: 5W12: 1113
30W7.5: 68
Resistor
A.C. GENERATOR
REMOVAL
Remove the right side cover. ( 2-4)
Remove the four bolts attaching the cooling
fan cover to remove the fan cover.
Fan Cover
14-6
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGIKITY 50
Remove the cooling fan by removing the four
cooling fan attaching bolts.
Cooling Fan
Hold the flywheel with an universal holder. Universal Holder
Remove the flywheel nut.
Special
Universal Holder
Remove the A.C. generator flywheel using
the flywheel puller.
Remove the woodruff key.
Special
Flywheel Puller
Flywheel Puller
A.C. Generator Wire Connector
Remove the A.C. generator wire connector.
14-7
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
Remove the A.C. generator wire set plate. Bolts
Remove the pulser coil bolts.
Remove the A.C. generator wire rubber
sleeve and pulser coil from the right
crankcase.
Remove the two bolts and A.C. generator
stator.
Bolts
A.C. GNERATOR INSTALLATION
Flywheel
Woodruff Key 5.5kg-m
Cooling Fan
0.9kg-m Fan Cover
0.5kg-m
A.C. Generator Wire Stator
Rubber Sleeve
Bolts Bolts
Install the A.C. generator stator and pulser
coil onto the right crankcase.
Tighten the stator and pulser coil bolts.
Torques: Pulser Coil : 0.45~0.6kgf-m
Stator : 0.8~1.2kgf-m
Install the A.C. generator wire rubber sleeve
and A.C. generator wire set plate.
14-8
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGIKITY 50
Connect the A.C. generator wire connector. A.C. Generator Wire Connector
Woodruff Key
Clean the taper hole in the flywheel off any
burrs and dirt.
Install the woodruff key in the crankshaft
keyway.
Universal Holder
Install the flywheel onto the crankshaft with
the flywheel hole aligned with the crankshaft
woodruff key.
The inside of the flywheel is magnetic.
Make sure that there is no bolt or nut
before installation.
Hold the flywheel with the universal holder
and tighten the flywheel nut.
Torque: 3.5~4.5kgf-m
Special
Universal Holder
Install the cooling fan.
Torque: 0.8~1.2kgf-m
Cooling Fan
14-9
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR AGILITY 50
Install the fan cover.
Install the right side cover. ( 2-4)
Fan Cover
14-10