17. BATTERY / CHARGING SYSTEM / A.C.

GENERATOR

BATTER/CHARGING SYSTEM /A.C. GENERATOR

SERVICE IMFORMATION ----------------------------------17-2

TROUBLESHOOTING ---------------------------------------17-3
BATTERY REMOVEAL ------------------------------------- 17-4
CHARGING SYSTEM --------------------------------------- 17-6
REGULATOR/RECTIFIER ----------------------------------17-8
A.C. GENERATOR CHARGING COIL -------------------17-9

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

Fuse/Battery

A.C.G Generator

Regulator/Rectifier

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

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 ~ 3years. 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 GS 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 machine for charging.
 When replacing the battery, do not use a traditional battery.
 When charging, check the voltage with a voltmeter.
SPECIFICATIONS
Item Standard
Capacity/ Model 12V-10AH
Voltage Fully charged 13.1V
Battery ( 20℃ ) Undercharged 12.3V
Charging current STD:1.2A Quick: 12A
Charging time STD: 5~ 10hr Quick: 30 min
A.C. Generator Capacity 210W
12.0~14.0V
Lighting
Regulator/Rectifier Limit voltage 10~ 13.0V
Charging 13.5~ 15.5V

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

TESTING INSTRUMENTS
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 of 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

SPECIAL TOOLS
Flywheel puller 71604-E20-000
Flywheel holder 71603-E10-000

TORQUE VALUES
AC magneto rotor nut 700 kg-cm (70Nm, 50 ft-lb)
Oneway clutch bolt 300 kg-cm (30Nm, 22 ft-lb)
AC magneto cover bolt 100 kg-cm (10Nm, 7.2 ft-lb)
Stator coil bolt 70 kg-cm (7Nm, 5.1 ft-lb)

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

BATTERY
REMOVAL/INSTALLATION

Make sure the ignition switch is OFF.

Remove the front carrier and cover.
（Refer chapter 2）

Front carrier

Front cover

Remove the two bolts and bracket.

Bracket Bolts

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

Battery
Disconnect the negative (-) terminal lead
from the battery first, then disconnect
the positive (+) terminal lead.

Remove the battery.

positive (+) negative (-)

＊
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.

INSTALLATION
1. Installation is in the reserve order of removal.

＊
First connect the positive (+) cable and then
negative (-) cable to avoid short circuit.

2. Make sure the battery is installed upright as shown.

3. Check all bolts and other fasteners are secure.
4. After installing the battery, check to see if the battery cables are routed correctly.

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

BATTERY VOLTAGE (OPEN CIRCUIT

VOLTAGE) INSPECTUIN
Remove the seat.
Disconnect the battery cables.
Measure the voltage between the battery
terminals.
Fully charged : 13.1V
Undercharged : 12.3V max
＊
Battery charging inspection must be
performed with a voltmeter.

CHARGING
Connecting the charger positive (+) cable to the
battery positive (+) terminal.
Connecting 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
current specified on the battery.

＊
 Quick charging should only be done in
an emergency.
 Measure the voltage 30 minutes after
the battery is charged.

Charging current: Standard: 1.2A

Quick : 3.0A
Charging time : Standard: 5 ~ 10 hours
Quick : 30 minutes
After charging: Open circuit voltage: 12.8 V min

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 17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

CHARGING SYSTEM
CURRENT LEAKAGE TEST
Remove the front rack and cover.
Turn the ignition switch “OFF”, and
disconnect the negative(-) cable from the
battery.
Connect the ammeter (+) probe to the
negative (-) cable and the ammeter (-) probe
to the battery(-) terminal.
With 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 not turn
the ignition switch “ON”. A sudden
surge of current may blow out the fuse
in the tester.
Specified current leakage:
1 mA maximum
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.

CHARGING VOLTAGE INSPECTION

Start the engine and warm it up to operating
temperature; stop the engine.
Connect the multi-meter between the
positive and negative terminals of the
battery.
＊ Make sure the battery is in good
condition before performing this test.
 To prevent a short, make absolutely
certain which are the positive and
negative terminals or cable.

With the headlight on high beam, restart the

engine. Measure the voltage on the
multimeter when the engine runs at 5000 rpm.
Limit Voltage/Current: 13.5 ~ 15.5 V/0.5A max
.

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

REGULATOR/RECTIFIER
INSPECTION
Remove the regulator/rectifier wire connectors.
Check the continuity between the wire terminals.

Regulator/rectifier Connectors Bolts

Regulator/rectifier

Normal Direction: Continuity

(+) probe (-)probe
I Green Yellow
II Yellow Red
Reverse Direction: No Continuity
(+) probe (-)probe
I Green Yellow
II Yellow Red

VOLTAGE REGULATION TEST

Connect a voltmeter across the battery terminals.

Start the engine and gradually increase the engine speed.

The battery terminal voltage should be within 14.0 ~ 15.0V.

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 17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

A.C. GENERATOR INSPECTION

＊
This test can be made without removing
the stator from the engine.

Disconnect the A.C. generator connector.

Check the continuity between the yellow
wires and ground.
There should be continuity between the
yellow wires and no continuity between
each yellow wire and ground.
Resistance (at 20 ℃):
Yellow ~ Yellow 500~700mΩ

Stator coil Screws

A.C.GENERATOR/FLYWHEEL
REMOVAL
Remove the magneto cover. (Refer to
the “WATER PUMP SHAFT REMOVAL”
section in the chapter 13)

Remove the pulse coil screw and then

remove the A.C. generator wire set plate.
Remove the Stator coil bolts and then
remove Stator coil and pulse coil from
magneto cover.

＊ When removing the pulse coil and

stator, be careful not to damage them to
avoid shorted or broken wire.

Bolts Pulse Coil

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

Remove the AC magneto nut  and washer.

＊
While holding the AC magneto rotor 
with the sheave holder , loosen the
AC magneto nut.
Do not allow the sheave holder to touch
the projection on the rotor.

Special
Flywheel holder 71603-E10-000
Flywheel puller 71604-E20-000

Remove the AC magneto rotor 

and starter clutch .
Remove the woodruff key.

＊
Use the flywheel puller.
Install the flywheel puller bolts to the
threaded holes of the starter clutch.
Make sure the flywheel puller is
centered over the AC magneto rotor.

CAUTION:
To protect the end of the crankshaft, place an appropriate sized socket between the flywheel
puller set center bolt and the crankshaft.

Damper assy


Starter idle gear


Two Washers
Washer
Starter wheel gear

Magneto rotor
Bolts
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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

Remove the nut and 3 bolts.

Disconnect the the AC magneto rotor

and starter clutch.

Check the stator coil and position sensor.

Damage  Replace

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

Check the starter one-way clutch.

Cracks / damage  Replace.

＊
Replace with a new one, and clinch
the end of the bolt .
The arrow mark on the starter clutch LOCTITE
must face inward, away from the AC
magneto rotor.

Bolt Torque: 300 kg-cm (30Nm, 22 ft-lb) / LOCTITE

A. Install the starter wheel gear to the starter clutch, and hold the starter clutch.
B. When turning the starter wheel gear counter clockwise A, the starter clutch
and the wheel gear should be engaged. If not, the starter clutch is faulty.
Replace it.
C. When turning the starter wheel gear clockwise B, the starter wheel gear
should turn freely. If not, the starter clutch is faulty. Replace it.

Starter idle gear

Check starter idle gear and wheel gear teeth.
Burrs / clips / roughness / wear Replace.
Check starter wheel gear contacting surface.
Damage / pitting / wear Replace.

Check damper assy.

Damage / wear Replace.

Damper assy

Starter wheel gear

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17. BATTERY / CHARGING SYSTEM / A.C. GENERATOR

INSTALLATION
Stator coil Screws
Install stator coil.
Tighten the bolts and screw

Bolt Torque: 70 kg-cm (7Nm, 5.1 ft-lb)

Bolts Pulser Coil

Install the woodruff key and AC magneto rotor A’ssy.

Install the washer and tighten the nut.
Nut Torque: 700 kg-cm (70Nm, 50 ft-lb)
＊
 Before installing the rotor, clean the
outside of the crankshaft and inside of
the rotor.
 After installing the rotor, check that
the rotor rotates smoothly. If not,
reinstall the key and rotor.

Install the AC magneto cover.

Tighten the 11 cover bolt.

Bolt Torque: 100 kg-cm (10Nm, 7.2 ft-lb)

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