NOTICE
Once the strip of caps is installed onto the battery,
never remove the caps, nor add water or electrolyte
to the battery.

NOTE

○Charging the battery immediately after filling can
shorten service life.

ELECTRICAL SYSTEM 16-29
Battery
Initial Charge
Newly activated sealed batteries require an initial charge.

•

Standard Charge: 0.9 A × 5  10 hours

If using a recommended battery charger, follow the
charger’s instructions for newly activated sealed battery.
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO2
Yuasa MB-2040/2060
Christie C10122S

•

If the above chargers are not available, use equivalent
one.
Let battery sit 30 minutes after initial charge, then check
voltage using a voltmeter. (Voltage immediately after
charging becomes temporarily high. For accurate measuring, let the battery sit for given time.)

NOTE

○Charging rates will vary depending on how long the
battery has been stored, temperature, and the type of
charger used. If voltage is not at least 12.6 V, repeat
charging cycle.
○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at
three times its amp-hour rating for 15 seconds.
Re-check voltage and if less than 12.6 V repeat the
charging cycle and load test. If still below 12.6 V the
battery is defective.
Precautions
1) No need of topping-up
No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying
off the seal cap to add water is very dangerous. Never do that.
2) Refreshing charge.
If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been
discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification
(see Refreshing Charge).
When a fast charge is inevitably required, do it following precisely the maximum charge current
and time conditions indicated on the battery.

NOTICE
This battery is designed to sustain no unusual deterioration if refresh-charged according
to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap
during refresh charge.
If by chance an excessive amount of gas is generated due to overcharging, the relief valve
releases the gas to keep the battery normal.
3) When you do not use the motorcycle for months.
Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage.
4) Battery life.
If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).

16-30 ELECTRICAL SYSTEM
Battery
DANGER
Batteries produce an explosive gas mixture of hydrogen and oxygen that can cause serious injury and burns if ignited. Keep the battery away from sparks and open flames during
charging. When using a battery charger, connect the battery to the charger before turning
on the charger. This procedure prevents sparks at the battery terminals which could ignite
any battery gases. The electrolyte contains sulfuric acid. Be careful not to have it touch
your skin or eyes. If touched, wash it off with liberal amount of water and seek medical
attention for more severe burns.

Interchange
A sealed battery can fully display its performance only when combined with a proper vehicle electric
system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with
a sealed battery.
Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original
equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

○Battery charging condition can be checked by measuring

•
•

battery terminal voltage with a digital meter [A].
Remove:
Battery (see Battery Removal)
Measure the battery terminal voltage.

NOTE

○Measure with a digital voltmeter which can be read one
decimal place voltage.
If the reading is 12.6 V or more, no refresh charge is required, however, if the read is below the specified, refresh
charge is required.
Battery Terminal Voltage
Standard: 12.6 V or more

Terminal Voltage (V) [A]
Battery Charge Rate (%) [B]
Refresh charge is required [C]
Note [D]
Good [E]

Refreshing Charge

the battery [A] (see Battery Removal).
• Remove
refresh charge by following method according to the
• Do
battery terminal voltage.

WARNING
This battery is sealed type. Never remove sealing
cap [B] even at charging. Never add water. Charge
with current and time as stated below.

ELECTRICAL SYSTEM 16-31
Battery
Terminal Voltage: 11.5  less than 12.6 V
Standard Charge: 0.9 A × 5  10 h (see following chart)
Quick Charge:

4A×1h

NOTICE
If possible, do not quick charge. If quick charge is
done unavoidably, do standard charge later on.
Terminal Voltage: less than 11.5 V
Charging Method: 0.9 A × 20 h

NOTE

○Increase the charging voltage to a maximum voltage of
25 V if the battery will not accept current initially. Charge
for no more than 5 minutes at the increased voltage then
check if the battery is drawing current. If the battery
will accept current decrease the voltage and charge by
the standard charging method described on the battery
case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A]
Battery Charger [B]
Standard Value [C]
Current starts to flow [D]
the battery condition after refresh charge.
•○Determine
Determine the condition of the battery left for 30 minutes
after completion of the charge by measuring the terminal
voltage according to the table below.
Criteria

Judgement

12.6 V or higher

Good

12.0  lower than 12.6 V

Charge insufficient → Recharge

lower than 12.0 V

Unserviceable → Replace

16-32 ELECTRICAL SYSTEM
Charging System
Alternator Cover Removal

• Drain:
Engine Oil (see Engine Oil Change in the Periodic Main•

tenance chapter)
Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Left Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Disconnect the alternator lead connector [A].

•
• Clear the alternator lead from the clamp [A].

a suitable container under the alternator cover [A].
• Place
Remove:
• Alternator Cover Bolts [B]
Bracket [C]
Alternator Cover

Alternator Cover Installation

a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket to the alternator lead grommet and
crankcase halves mating surface [A] on the front and rear
sides of the cover mount.
Sealant - Liquid Gasket, TB1211F: 92104-0004

that dowel pins [B] are in place on the crankcase.
• Check
Replace
• Tighten: the alternator cover gasket with a new one.
•
Torque - Alternator Cover Bolts: 12 N·m (1.2 kgf·m, 106
in·lb)

the alternator lead correctly (see Cable, Wire, and
• Run
Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).

ELECTRICAL SYSTEM 16-33
Charging System
Stator Coil Removal

• Remove:
Alternator Cover (see Alternator Cover Removal)
•

Alternator Lead Holding Plate Bolt [A] and Plate
Alternator Lead Grommet [B]
Stator Coil Bolts [C]
Remove the stator coil [D] from the alternator cover.

Stator Coil Installation

a non-permanent locking agent to the threads of
• Apply
the stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

the alternator lead with a holding plate [A].
• Secure
Apply
a
locking agent to the threads of
• the platenon-permanent
bolt [B] and tighten it.
Torque - Alternator Lead Holding Plate Bolt: 12 N·m (1.2
kgf·m, 106 in·lb)

a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket to the circumference of the alternator
lead grommet [C], and fit the grommet into the notch of
the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004

the alternator cover (see Alternator Cover Installa• Install
tion).

Alternator Rotor Removal

• Remove:
Alternator Cover (see Alternator Cover Removal)
Starter Idle Gear [A] and Shaft [B]

the alternator rotor steady with the rotor holder [A]
• Hold
and stopper [B].
• Remove the rotor bolt [C] and washer.
Special Tools - Grip [D]: 57001-1591
Stopper: 57001-1679
Rotor Holder: 57001-1690

16-34 ELECTRICAL SYSTEM
Charging System
the flywheel puller [A], remove the alternator rotor
• Using
[B] from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615

NOTICE
Do not attempt to strike the alternator rotor itself.
Striking the rotor can cause the magnets to lose
their magnetism.

Alternator Rotor Installation

a thin coat of molybdenum disulfide grease to the
• Apply
crankshaft [A] and the outer surface [B] of the starter
clutch gear [C].

the starter clutch gear [A].
• Install
Using
a
cleaning fluid, clean off any oil or dirt on the fol• lowing portions
and dry them with a clean cloth.
Crankshaft Tapered Portion [B]
Alternator Rotor Tapered Portion [C]
Fit the woodruff key [D] securely in the slot in the crankshaft.
○Align the woodruff key with the key way [E] to install the
alternator rotor.

•

the alternator rotor [A] while turning [B] the starter
• Install
clutch gear [C] clockwise.

a cleaning fluid, clean off any oil or dirt on the
• Using
washer [A] and dry it with a clean cloth.
• Install the washer.

NOTE

○Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.
the rotor bolt [B] and tighten it with 70 N·m (7.0
• Install
kgf·m, 52 ft·lb) of torque.

ELECTRICAL SYSTEM 16-35
Charging System
the rotor bolt and washer.
• Remove
Check
the
tightening torque with flywheel puller [A].
•
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1615

If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15
ft·lb) of drawing torque, clean off any oil dirt or flaw of the
crankshaft and rotor tapered portion, and dry them with
a clean cloth. Then, confirm that it is not pulled out with
above torque.
the washer and rotor bolt.
• Install
Tighten
the alternator rotor bolt [A] while holding the alter• nator rotor
steadily with the holder [B].
Special Tools - Grip [C]: 57001-1591
Stopper [D]: 57001-1679
Rotor Holder: 57001-1690
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)

a thickness gauge, make sure the clearance [A]
• Using
between the starter clutch gear [B] and the starter clutch
race [C] is 0.4 mm (0.02 in.) or more.
If the clearance is less than 0.4 mm (0.02 in.), remove the
rotor and starter clutch race, and then clean them thoroughly and reinstall them.

a thin coat of molybdenum disulfide grease to the
• Apply
shaft [A], and install it with the starter idle gear [B].
the alternator cover (see Alternator Cover Installa• Install
tion).

16-36 ELECTRICAL SYSTEM
Charging System
Charging Voltage Inspection

the battery condition (see Charging Condition In• Check
spection).
up the engine to obtain actual alternator operating
• Warm
conditions.
the front seat (see Front Seat Removal in the
• Remove
Frame chapter).
that the ignition switch is turned off, and connect a
• Check
tester [A] to the battery terminals [B].
the engine, and note the voltage readings at various
• Start
engine speeds (except idling engine speed) with the
headlight turned on and then turned off (To turn off the
headlight, disconnect the headlight connector on the
headlight unit.). The readings should show nearly battery
voltage when the engine speed is low, and, as the engine
speed rises, the readings should also rise. But they must
be kept under the specified voltage.
Charging Voltage

@25°C (77°F)

Connections
Tester (+) to

Tester (–) to

Battery (+)

Battery (–)

Reading
DC 14.5  14.9 V

off the ignition switch to stop the engine, and discon• Turn
nect the tester.
If the charging voltage is kept between the values given in
the table, the charging system is considered to be working
normally.
If the charging voltage is much higher than the values
specified in the table, the regulator/rectifier is defective
or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed
increases, then the regulator/rectifier is defective or the
alternator output is insufficient for the loads. Check the
alternator and regulator/rectifier to determine which part
is defective.

Alternator Inspection
There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output,
or no output at all. A loss in rotor magnetism, which may be
caused by dropping or hitting the alternator, by leaving it
near an electromagnetic field, or just by aging, will result in
low output.

ELECTRICAL SYSTEM 16-37
Charging System
check the alternator output voltage, do the following
• To
procedures.

○Turn the ignition switch off.
○Remove the fuel tank (see Fuel Tank Removal in the Fuel
System (DFI) chapter).
○Disconnect the alternator lead connector [A].
○Connect a tester as shown in the table 1.
○Install the fuel tank temporary (see Fuel Tank Installation
in the Fuel System (DFI) chapter).
○Start the engine.
○Run it at the rpm given in the table 1.
○Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Connections
Tester (+) to

Tester (–) to

One Black lead

Another Black lead

@4 000 r/min (rpm)
Reading
AC 41.6  62.4 V

If the output voltage shows the value in the table, the alternator operates properly.
If the output voltage shows a much lower reading than
that given in the table, stop the engine and inspect the
stator coil resistance.
Check the stator coil resistance as follows.
○Stop the engine.
○Connect the tester as shown in the table 2.
○Note the readings (total 3 measurement).

•

Table 2 Stator Coil Resistance
Connections
Tester (+) to

Tester (–) to

One Black lead

Another Black lead

@20°C (68°F)
Reading
0.176  0.264 Ω

measuring the resistance, use a tester that can
• When
measure the standard value.

•

If there is more resistance than shown in the table, or
no tester reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
replaced.
Measure the resistance between each of the black leads
and chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating stator replacement.
If the stator coils have normal resistance, but the voltage
check showed the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
replaced.

16-38 ELECTRICAL SYSTEM
Charging System
Regulator/Rectifier Removal

• Remove:
Left Middle Fairing (see Middle Fairing Removal in the
•
•

Frame chapter)
Disconnect the connector [A].
Remove:
Regulator/Rectifier Bolts [B]
Regulator/Rectifier [C]

Regulator/Rectifier Installation

• Install:
Regulator/Rectifier [A]
•

Nut Plates [B]
Regulator/Rectifier Bolts [C]
Install the left middle fairing (see Middle Fairing Installation in the Frame chapter).

Regulator/Rectifier Inspection

to the Charging System Troubleshooting for the
• Refer
Regulator/Rectifier Inspection.
Charging System Troubleshooting
Before inspection, remove all accessories that consume
electrical power.

•

NOTE

○Even when the charging system is working properly, the
battery may discharge if the motorcycle is equipped with
too many accessories.
attention to riding conditions and the customer’s rid• Pay
ing habits which could affect the charging system such
as:
Frequent use at low engine
speed
Frequent and unnecessary brake
pedal dragging

→ Battery Discharged

• Recharge the battery if it is discharged.

ELECTRICAL SYSTEM 16-39
Charging System

16-40 ELECTRICAL SYSTEM
Charging System
Charging System Circuit

1. Ignition Switch
2. Load
3. Frame Ground (3)
4. Engine Ground
5. Battery 12 V 8 Ah
6. Starter Relay
7. Main Fuse 30 A
8. Regulator/Rectifier
9. Alternator

ELECTRICAL SYSTEM 16-41
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, stick coil or stick
coil lead while the engine is running, or you could
receive a severe electrical shock.