15. ELECTRICAL EQUIPMENT SUPER 9 50 - The Cinnamons 15 - Electrical Equipment.pdf · operation of the auto bystarter. ... 15. ELECTRICAL EQUIPMENT 15-12 SUPER 9 50 STARTER RELAY INSPECTION

15. ELECTRICAL EQUIPMENT

15-0

SUPER 9 50

15 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

ELECTRICAL EQUIPMENT__________________________________________________________________________________

SERVICE INFORMATION........................................................ 15- 1

TROUBLESHOOTING.............................................................. 15- 1

CHARGING SYSTEM............................................................... 15- 3

BATTERY................................................................................ 15- 4

IGNITION SYSTEM ................................................................. 15- 7

STARTING SYSTEM................................................................ 15-11

15

15. ELECTRICAL EQUIPMENT

15-1

SUPER 9 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• It is not necessary to check the battery electrolyte or fill with distilled water.• Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap..• Do not quick charge the battery. Quick charging should only be done in an emergency..• Charge the battery according to the charging current and time specified on the battery.• When charging, check the voltage (open voltage) with an electric tester.• When replacing the battery, do not use a traditional battery.

SPECIFICATIONS SH10DA SF10DA

Capacity 12V4AH 12V4AH

Voltage 13.0_ 13.2V 13.0_ 13.2V

Charging Standard 0.4A/5H 0.4A/5HBattery

current Quick 5A/0.5H 4A/0.5H

Spark plug (NGK) BR8HSA BR8HSA

Spark plug gap 0.6_ 0.7mm 0.6_ 0.7mm

Primary coil 0.153_ 0.187W 0.153_ 0.187WSecondary coil(with plug cap) 6.99_ 10.21KW 6.99_ 10.21KWIgnition coil resistanceSecondary coil(without plug cap) 3.24_ 3.96KW 3.24_ 3.96KW

Pulser coil resistance (20℃ ) 80_ 160W 80_ 160W

Ignition timing 13.5°±2°BTDC/1800rpm13.5°±2°BTDC/2000rpm

TROUBLESHOOTING

CHARGING SYSTEM

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 ignition system• Faulty ignition switch • Loose connection or short circuit in 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

15. ELECTRICAL EQUIPMENT

15-2

SUPER 9 50

IGNITION SYSTEM

No spark at plug Engine starts but turns poorly• Faulty spark plug • Ignition primary circuit• Poorly connected, broken or shorted wire óFaulty ignition coilóBetween A.C. generator and CDI unit óPoorly connected wire or connectoróBetween CDI unit and ignition coil • Ignition secondary circuitóBetween CDI unit and ignition switch óFaulty ignition coilóBetween ignition coil and spark plug óFaulty spark plug

• Faulty ignition switch óPoorly insulated plug cap• Faulty ignition coil • Improper ignition timing• Faulty CDI unit óBattery voltage too low (6V max.)• Faulty A.C. generator óFaulty CDI unit

STARTING SYSTEM

Starter motor won‘t turn Lack of power• Fuse burned out • Weak battery• Weak battery • Loose wire or connection• Faulty ignition switch • Foreign matter stuck in starter motor• Faulty starter switch or pinion

• Faulty front or rear stop switch Starter motor rotates but engine does• Faulty starter relay not start• Poorly connected, broken or shorted wire • Faulty starter pinion• Faulty starter motor • Starter motor rotates reversely

• Faulty starter clutch• Weak battery

15. ELECTRICAL EQUIPMENT

15-3

SUPER 9 50

CHARGING SYSTEM

5. 9W30W

Resistor

15. ELECTRICAL EQUIPMENT

15-4

SUPER 9 50

BATTERYBATTERY REMOVALOpen the front tool box and remove the bolt.Remove the front tool box. (!2-4)Disconnect the battery cables.

Remove the bolt and battery bracket.Remove the battery.The installation sequence is the reverse ofremoval.BATTERY CHARGING (OPEN CIRCUITVOLTAGE) INSPECTIONRemove the battery cover and disconnect thebattery cables.Measure the voltage between the batteryterminals.Fully charged : 13.0V_ 13.2VUndercharged : 12.3V max.

CHARGING METHODConnect the charger positive (+) cable to thebattery positive (+) cable.Connect the charger negative (-) cable to thebattery negative (-) cable.

Charging current : Standard : 0.4AQuick : 4A

Charging time : Standard : 5 hoursQuick : 0.5 hours

After charging: Open circuit voltage: 12.8V min.

Front Tool Box

First disconnect the battery negative (-)cable and then the positive (+) cable.

＊

Battery charging inspection must beperformed with an electric tester.

＊

• Quick charging should only be done inan emergency.

• During quick charging, the batterytemperature should not exceed45℃ .

• Measure the voltage 30 minutes afterthe battery is charged.

＊

• Keep flames and sparks awayfrom a charging battery.

• Turn power ON/OFF at thecharger, not at the battery terminals toprevent sparks near the battery.

• Charge the battery according tothe current specified on the batterysurface.

＊

Power Lamp (Green)

Red

Black

Charging Lamp (Red)

Battery

15. ELECTRICAL EQUIPMENT

15-5

SUPER 9 50

PERFORMANCE TESTWarm up the engine.Remove the floor mat and battery cover.

Stop the engine and open the fuse box.Disconnect the wire lead from the fuseterminal. Connect an ammeter between thewire lead and fuse terminal as shown.Connect the battery positive (+) terminal tothe voltmeter positive (+) probe and batterynegative (-) terminal to the voltmeter negative(-) probe.Start the engine, gradually increase enginespeed to test the output:

PositionRPM

Day Night

2500 1.3A min. 1.0A min.

6000 2.0A min. 2.0A min.

Charging Limit Voltage: 14.5±0.5V/8000rpmIf the limit voltage is not within the specifiedrange, check the regulator/ rectifier.

A.C. GENERATOR (CHARGINGCOIL) INSPECTION

Remove the met-in box, rear carrier and framebody cover. (!2-2)Disconnect the A.C. generator connector.Measure the resistances between the chargingcoil terminals (whiteñgreen) and lighting coilterminals (yellowñgreen).Resistances:

Charging coil whiteñgreen 0.2_ 1.2W

Lighting coil yellowñgreen 0.3_ 1.0W

Refer to 8-3 for A.C. generator removal.

A.C. Generator Connector

Use a fully charged battery to check thecharging system output.

＊

Inspect with the engine installed.＊

15. ELECTRICAL EQUIPMENT

15-6

SUPER 9 50

RESISTOR INSPECTIONRemove the front upper/lower cover. (!2-3)Measure the resistance between the resistor Bpink wire and ground.Measure the resistance between the resistorA green/black wire and ground.Resistances: Resistor A: 9.9_ 10.5W Resistor B: 5.6_ 6.2W

REGULATOR/RECTIFIERINSPECTIONRemove the front upper/lower cover. (!2-3)Disconnect the regulator/rectifier wire couplerand remove the bolt to remove theregulator/rectifier.

Measure the resistances between theterminals.Replace the regulator/rectifier if the readingsare not within the specifications in the tablebelow.

Model Brand Range

SP-10D Sanwa KW

TH-5H Kowa 100W

Probe⊕Probe(-) A (R) B (W) C (Y) D (G)

A (R) ∞ ∞ ∞

B (W) 3-10KW ∞ ∞

C (Y) ∞ ∞ 33-35KW

D (G) ∞ ∞ 33-35KW

• Due to the semiconductor in circuit, itis necessary to use a specified testerfor accurate testing. Use of animproper tester in an improper rangemay give false readings.

• Use a Sanwa Electric Tester (07208-0020000) or Kowa Electric Tester(TH-5H). The proper range fortesting is listed below.

＊

Coupler

Faulty resistor is the cause of faultyoperation of the auto bystarter.

＊

A (Red) C (Yellow)

D (Green)B (White)

Resister A Resister B

Regulator/Rectifier

Bolt

15. ELECTRICAL EQUIPMENT

15-7

SUPER 9 50

IGNITION SYSTEM

15. ELECTRICAL EQUIPMENT

15-8

SUPER 9 50

IGNITION COIL INSPECTIONContinuity Test

Remove the met-in box. (!12-4)Measure the resistance between the ignitioncoil primary coil terminals.Resistance (20℃ ): 0.153_ 0.187W

Measure the secondary coil resistancebetween the spark plug cap and the primarycoil terminal as Figure A shown.Resistance (20℃ ) (with plug cap):6.99_ 10.21KW

Measure the secondary coil resistancebetween the ignition coil terminal and theprimary coil terminal as Figure B shown.Resistance (20℃ ) (without plug cap):3.24_ 3.96KW

This test is to inspect the continuity ofignition coil.

＊

Ignition Coil

GreenBlack

15. ELECTRICAL EQUIPMENT

15-9

SUPER 9 50

Performance TestRemove the ignition coil.

Inspect the ignition coil with an ignition coiltester.

1. Turn the changeover switch to 12V andconnect the ignition coil to the tester.

2. Turn the power switch ON and check thespark from the watch window._Good : Normal and continuous spark_Faulty : Weak or intermittent spark

A.C. GENERATOR

Exciter Coil/Pulser Coil Inspection

Remove the met-in box. (!12-4)Disconnect the A.C. generator wireconnector.Measure the pulser coil resistance betweenthe blue/yellow wire and ground.Resistance (20℃ ): 80_ 160W

Ignition Coil

AC 110V6V/12VChangeoverSwitch

Ignition Coil Tester07508-0070100

Watch Window

Black

Black(-)

Red(+)

Black(-)

Red(+)

Blue/Yellow

This test is performed with the statorinstalled in the engine.

＊

Follow the ignition coil tester manufac-turer‘s instructions.

＊

The test is performed at both conditionsthat the ignition coil is cold and hot.

＊

15. ELECTRICAL EQUIPMENT

15-10

SUPER 9 50

CDI UNIT INSPECTIONOpen the front tool box and remove the bolt.Remove the front tool box. (!2-4)Disconnect the CDI coupler and remove theCDI unit.

CDI CIRCUIT INSPECTIONMeasure the resistance between the terminals.Replace the CDI unit if the readings are notwithin the specifications in the table below.

Use the x KW range for the Sanwa Tester.Use the x 100W range for the Kowa Tester.

Unit: KWProbe⊕

(-)Probe

Black/Blue

Blue/Yellow

Green Black/Yellow

Black/Blue ∞ 1~100 ∞

Blue/Yellow 100~

∞1~100 ∞

Green 1~∞ ∞ ∞

Black/Yellow 1~100 ∞ 0.1~50

• Due to the semiconductor in circuit, it isnecessary to use a specified tester foraccurate testing. Use of an impropertester in an improper range may givefalse readings.

• Use a Sanwa Electric Tester or KowaElectric Tester (TH-5H).

• In this table, “Needle swings thenreturns” indicates that there is a chargingcurrent applied to a condenser. The needlewill then remain at “∞ ” unless thecondenser is discharged.

＊

CDI Unit

Blue/ Yellow

Green

Black/ Blue

Black/ Yellow

Coupler

15. ELECTRICAL EQUIPMENT

15-11

SUPER 9 50

STARTING SYSTEM

15. ELECTRICAL EQUIPMENT

15-12

SUPER 9 50

STARTER RELAY INSPECTIONOpen the front tool box and remove the bolt.Remove the front tool box. (!2-4)Disconnect the starter relay coupler and thenremove the starter relay.

Connect the starter relay green/yellowterminal to the 12V battery positive (+)terminal and the relay yellow/red terminal tothe battery negative (-) terminal. Check forcontinuity between the starter relay red andred/white terminals. The relay is normal ifthere is continuity.

STARTER MOTOR REMOVALDisconnect the starter motor cable.Remove the two bolts attaching the startermotor and remove the starter motor.The installation sequence is the reverse ofremoval.

AC 110V

Starter Relay

Green/Yellow

Starter Motor

Red/White

Bolts

Yellow/RedRed

15. ELECTRICAL EQUIPMENT

15-13

SUPER 9 50

STARTER MOTOR INSPECTIONConnect a battery across the starter motorand check for its operation.

1. Do not turn the starter motor for along time.

2. This inspection should be done with afully charged battery.

＊

Battery

Starter Motor Battery (+) Terminal