the projections [A] of the heat insulator plate from
• Detach
the main frame to remove the alternator lead.

• Open the clamp [A] and free the alternator lead.

• Remove:
Alternator Cover Bolts [A]
Clamp [B]
Alternator Cover [C]

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

• Check that dowel pins [B] are in place on the crankcase.

16-30 ELECTRICAL SYSTEM
Charging System
the alternator cover gasket with a new one.
• Replace
Install
the
alternator cover [A] and the clamp [B].
•○Fit the clamp
to the side [C] of the alternator cover.
Tighten:
•
Torque - Alternator Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

the leads correctly and connect the alternator lead
• Run
connector (see Cable, Wire, and Hose Routing section in
the Appendix chapter).

Stator Coil Removal

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

Alternator Lead Holding Plate Bolt [A] and Plate [B]
Alternator Lead Grommet [C]
Stator Coil Bolts [D]
Remove the stator coil [E] 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)

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 [A], and fit the grommet into the notch of
the cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004

the alternator lead with the holding plate [B].
• Secure
Apply
a
locking agent to the threads of
• the platenon-permanent
bolt [C] and tighten it.
Torque - Alternator Lead Holding Plate Bolt: 10 N·m (1.0
kgf·m, 89 in·lb)

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

Alternator Rotor Removal

the alternator cover (see Alternator Cover Re• Remove
moval).
the alternator rotor steady with the rotor holder [A]
• Hold
and suitable washer [B] or plate.
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1666
Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5 [D]: 57001-1405
Rotor Holder Attachment: 57001-1689

ELECTRICAL SYSTEM 16-31
Charging System
Suitable Washer [A] (Aluminum)
Inside Diameter [B]: 40 mm (1.6 in.)
Outside Diameter [C]: 60 mm (2.4 in.)
Thickness: About 2 mm (0.08 in.)

the alternator rotor bolt and washer.
• Remove
Using
the
flywheel puller [A], remove the alternator rotor
• from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405

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 cleaning fluid, clean off any oil or dirt on the fol• Using
lowing portions and dry them with a clean cloth.

•

Crankshaft Tapered Portion [A]
Alternator Rotor Tapered Portion [B]
Install the alternator rotor.

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

NOTE

○Confirm the alternator rotor fit or not to the crankshaft
before tightening it with specified torque.

the alternator rotor bolt with 70 N·m (7.0 kgf·m,
• Tighten
52 ft·lb) of torque while holding the alternator rotor steady
with the rotor holder [A] and suitable washer [B] or plate.
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1666
Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5 [D]: 57001-1405
Rotor Holder Attachment: 57001-1689

16-32 ELECTRICAL SYSTEM
Charging System
the alternator rotor bolt and washer.
• Remove
Check
the
tightening torque with flywheel puller [A].
•
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5: 57001-1405

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 alternator rotor bolt.
• Install
the alternator rotor bolt while holding the alterna• Tighten
tor rotor steadily with the holder [A] and suitable washer
[B] or plate.
Special Tools - Grip [C]: 57001-1591
Rotor Holder: 57001-1666
Flywheel Puller Assembly, M38 × 1.5/M35 ×
1.5 [D]: 57001-1405
Rotor Holder Attachment: 57001-1689
Torque - Alternator Rotor Bolt: 155 N·m (15.8 kgf·m, 114
ft·lb)

ELECTRICAL SYSTEM 16-33
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.). 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

@20°C(68°F)

Connections
Tester (+) to

Tester (–) to

Battery (+)

Battery (–)

Reading
DC 14.3  14.7 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 leads 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.

16-34 ELECTRICAL SYSTEM
Charging System
check the alternator output voltage, do the following
• To
procedures.

○Turn the ignition switch off.
○Remove the left inner cover (see Inner Cover Removal in
the Frame chapter).
○Disconnect the alternator lead connector [A].
○Connect a tester as shown in the table 1.
○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 W lead

Another W lead

@4 000 r/min (rpm)
Reading
AC 48  72 V

If the output voltage shows the value in the table, the alternator operates properly. The regulator/rectifier is damaged.
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 a tester as shown in the table 2.
○Note the readings (total 3 measurements).

•

Table 2: Stator Coil Resistance
Connections
Tester (+) to

Tester (–) to

One W lead

Another W lead

@20°C (68°F)
Reading
0.110  0.164 Ω

When measuring the resistance, use a tester that can
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 white leads
and chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating stator replacement.
If the stator coil has 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.

•

ELECTRICAL SYSTEM 16-35
Charging System
Regulator/Rectifier Removal

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
•
•

Removal in the Frame chapter)
Disconnect the regulator/rectifier connectors [A].
Remove:
Nuts [B]
Regulator/Rectifier [C]

Regulator/Rectifier Installation
the regulator/rectifier.
• Install
• Tighten:

Torque - Regulator/Rectifier Mounting Nuts: 7.0 N·m (0.71
kgf·m, 62 in·lb)

the regulator/rectifier connectors.
• Connect
Install
the
removed parts (see appropriate chapters).
•

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.

16-36 ELECTRICAL SYSTEM
Charging System

ELECTRICAL SYSTEM 16-37
Charging System
Charging System Circuit

1. Ignition Switch
2. Load
3. Regulator/Rectifier
4. Alternator
5. Frame Ground
6. Starter Relay
7. Main Fuse 30 A
8. Battery 12 V 8.6 Ah

16-38 ELECTRICAL SYSTEM
Ignition System
WARNING
The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil or ignition coil lead while the engine is running, or you
could receive a severe electrical shock.

NOTICE
Do not disconnect the battery cables or any other
electrical connections when the ignition switch is
on, or while the engine is running. This is to prevent
ECU damage.
Do not install the battery backwards. The negative
side is grounded. This is to prevent damage to the
ECU.

Crankshaft Sensor Removal

• Remove:
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
Right Lower Fairing (see Lower Fairing Removal in the
Frame chapter)
Crankshaft Sensor Lead Connector [A]
Water Temperature Sensor Connector [B]

the clamp [A], and disconnect the oil pressure
• Open
switch terminal [B].
• Remove:
Crankshaft Sensor Cover Bolts [C]
Clamp [D]
Crankshaft Sensor Cover [E]

• Remove:
Crankshaft Sensor Bolts [A]
Crankshaft Sensor Lead Grommet [B]
Crankshaft Sensor [C]

ELECTRICAL SYSTEM 16-39
Ignition System
Crankshaft Sensor Installation

a non-permanent locking agent to the crankshaft
• Apply
sensor bolts [A].
•○Tighten:
When installing the sensor which is fastened by bolts,
tighten the bolts after placing the sensor on the bottom
surface completely.
Torque - Crankshaft Sensor Bolts: 6.0 N·m (0.61 kgf·m, 53
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 crankshaft
sensor lead grommet [B], and fit the grommet into the
notch of the crankshaft sensor cover securely.
Sealant - Liquid Gasket, TB1211F: 92104-0004

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 crankcase mating surface [A]
on the front and rear sides of the cover mount.
Sealant - Liquid Gasket, TB1211F: 92014-0004

• Check that dowel pins [B] are in place on the crankcase.
the crankshaft sensor cover gasket with a new
• Replace
one.
the crankshaft sensor cover [A] and the clamp [B].
•○Install
Run the crankshaft sensor lead to the inside of the rib [C].
• Tighten:
Torque - Crankshaft Sensor Cover Bolts:
kgf·m, 89 in·lb)

10 N·m (1.0

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

16-40 ELECTRICAL SYSTEM
Ignition System
Crankshaft Sensor Inspection

the crankshaft sensor lead connector [A] (see
• Disconnect
Crankshaft Sensor Removal).
a tester [B], and connect it to the crankshaft sensor
• Set
lead connector.
Crankshaft Sensor Resistance
Connections:
Meter (+) → Y lead
Meter (–) → BK lead
Standard:

•

376  564 Ω @20°C (68 °F)

If there is more resistance than the specified value, the
coil has an open lead and must be replaced. Much less
than this resistance means the coil is shorted, and must
be replaced.
Using the highest resistance range of the tester, measure
the resistance between the crankshaft sensor leads and
chassis ground.
Any tester reading less than infinity (∞) indicates a short,
necessitating replacement of the crankshaft sensor.

Crankshaft Sensor Peak Voltage Inspection
NOTE

○Be sure the battery is fully charged.
○Using the peak voltage adapter [A] is more reliable way
to determine the condition of the crankshaft sensor than
crankshaft sensor internal resistance measurements.
the crankshaft sensor lead connector (see
• Disconnect
Crankshaft Sensor Removal).
• Set a tester [B], and connect it to the peak voltage adapter.
Special Tool - Peak Voltage Adapter: 57001-1415
Type: KEK-54-9-B

the adapter to the terminals of the crankshaft
• Connect
sensor lead connector [C].
Connections:
Crankshaft Sensor
Lead Connector

Peak Voltage
Adapter

Tester

Y lead

←

R lead

→

(+)

BK lead

←

BK lead

→

(–)

the engine stop switch to run position.
• Turn
Turn
the ignition switch on.
• Pushing
the starter button, turn the engine 4  5 seconds
• with the transmission
in neutral to measure the peak volt-

•

age.
Repeat the measurements 5 times or more times.
Crankshaft Sensor Peak Voltage
1.9 V or more
Standard:

If the reading is less than the standard, inspect the crankshaft sensor (see Crankshaft Sensor Inspection).

ELECTRICAL SYSTEM 16-41
Ignition System
Timing Rotor Removal

the crankshaft sensor cover (see Crankshaft
• Remove
Sensor Removal).
the timing rotor [A].
•○Remove
Holding the timing rotor with the flywheel & pulley holder
[B] and unscrew the bolt [C].
Special Tool - Flywheel & Pulley Holder: 57001-1605

Timing Rotor Installation

the timing rotor [A] on the crankshaft [B] with their
• Install