14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-0
Mongoose/KXR 90/50
14
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
BATTER/CHARGING SYSTEM/
A.C. GENERATOR
__________________________________________________________________________________
SERVICE INFORMATION -------------------------------------------- 14- 2
BATTERY REMOVAL ------------------------------------------------- 14- 4
CHARGING SYSTEM -------------------------------------------------- 14- 6
REGULATOR/RECTIFIER -------------------------------------------- 14- 7
A.C. GENERATOR CHARGING COIL-------------------------------- 14- 8
A.C. GENERATOR LIGHTING COIL-------------------------------- 14- 8
RESISTOR INSPECTION---------------------------------------------- 14- 8
A.C. GENERATOR ----------------------------------------------------- 14- 8
14
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-1
Mongoose/KXR 90/50
CHARGING CIRCUIT
Regulator/Rectifier
A.C. Generator
Regulator/
Rectifier
A.C. Generator
Headlight Switch
YRG
Battery
12V4AH
Y
Auto
Bystarter
G/B
W
G
90cc:
12W5W
50cc:
10.2W5W
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-2
Mongoose/KXR 90/50
SERVICE INFORMATIONN
GENERAL INSTRUCTIONS
• 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 2_ 3 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.
SPECIFICATIONS
Item
Standard
ATV Name &Type
Mongoose/KXR 90
Mongoose/KXR 50
Capacity/Model
12V4AH
Voltage
Fully charged
13.1V
Battery
(20¢J )
Undercharged
12.3V
Charging current
STD: 0.4A Quick: 4.0A
Charging time
STD: 5_ 10hr Quick: 30min
A.C. Generator
Capacity
150W
Charging
14.5±0.5V
Regulator/Rectifier
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
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-3
Mongoose/KXR 90/50
TESTING INSTRUMENTS
Electric tester: YF-3051
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. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-4
Mongoose/KXR 90/50
BATTERY REMOVAL
Remove seat. (See page 2-3)
Remove the battery cover, by removing the
mount bolts. (Make sure the ignition switch
is OFF)
Remove the battery by removing the bolts.
First disconnect the battery negative (-)
cable and then the positive (+) cable.
The installation sequence is the reverse of
removal.
BATTERY VOLTAGE (OPEN CIRCUIT
VOLTAGE) INSPECTION
Remove the seat. (See page 2-3)
Disconnect the battery cables.
Measure the voltage between the battery
terminals.
Fully charged : 13.1V
Undercharged : 12.3V max
Bolts
Negative (-) Cable
Positive (+) Cable
Battery charging inspection must be
performed with a voltmeter.
°Ø
Battery Cover
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.
First connect the positive (+) cable and then
negative (-) cable to avoid short circuit.
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-5
Mongoose/KXR 90/50
CHARGING
Connect the charger positive (+) cable to the
battery positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-) terminal.
Charging current : Standard : 0.4A
Quick : 4.0A
Charging time : Standard : 5_ 10 hours
Quick : 30 minutes
After charging: Open circuit voltage: 12.8V min.
• 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
• Quick charging should only be done in
an emergency.
• Measure the voltage 30 minutes after
the battery is charged.
°Ø
Power Lamp (Red)
Charging Lamp
(Green)
Red
Black
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-6
Mongoose/KXR 90/50
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.
If any abnormality is found, check the ignition
switch and wire harness for short circuit.
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 red wire from the
fuse terminal and connect an ammeter
between the red wire lead and the fuse
terminal as shown.
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:
13.5_ 15.5V/0.5
A max. (5000rp m
max.)
If the limit voltage is not within the
specified range, check the regulator/rectifier.
Connect the electric tester positive (+)
terminal to ground wire and the tester
negative (-) terminal to the battery
negative (-) terminal.
°Ø
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-7
Mongoose/KXR 90/50
REGULATOR/RECTIFIER
MAIN HARNES S CIRCUIT INS PECTION
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)
and engine ground
Battery has
voltage
Between ground (green)
and engine ground
Continuity exists
Between lighting wire
(yellow) and engine
ground (Remove the
resistor coupler and auto
bystarter coupler and
turn the lighting switch
OFF for inspection)
A.C. generator
stator has
resistance
Between charging coil
(white) and engine
ground
A.C. generator
stator has
resistance
REGULATOR/RECTIFIER INS PECTION
If the main harness terminals are normal,
check the regulator/rectifier coupler for loose
connection and measure the resistances
between the regulator/rectifier terminals.
Replace the regulator/rectifier if the readings
are not within the specifications in
the table.
Probe⊕
Probe(-)
White
Yellow
Red
Green
White°¤°¤
°¤
Yellow
°¤°¤10.75M
Red
6.62M
°¤
°¤
Green
°¤
11.17M
°¤
• 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.
Testing instrument
YF-3501
• If the dry battery in the tester is weak,
the readings will be incorrect. In this
case, check the dry battery.
＊
Regulator/Rectifier
Yellow
Red
Green
White
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-8
Mongoose/KXR 90/50
A.C. GENERATOR CHARGING
COIL
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 (YF-3501 tester).
Standard: 2.2W(at 20¢J)
Replace the A.C. generator charging coil if
the reading is not within the specifications.
A.C. GENERATOR LIGHTING
COIL
INSPECTION
Disconnect the A.C. generator 2P connector.
Measure the resistance between the A.C.
generator yellow wire and engine ground
with an electric tester (YF-3501 tester).
Standard: 3.1W (20¢J)
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:
Mongoose/KXR 90: 5W12W
30W7.5W
Mongoose/KXR 50: 5W10.2W
30W5.9W
A.C. GENERATOR
REMOVAL
Remove the four bolts attaching the cooling
fan cover.
Remove the fan cover.
The inspection of A.C. generator charging
coil can be made with the engine installed.
＊
The inspection of A.C. generator lighting
coil can be made with the engine installed.
＊
Charging Coil Wire
Lighting Coil Wire
Resistor
Fan Cover
Bolts
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-9
Mongoose/KXR 90/50
Remove the cooling fan by removing the
four cooling fan attaching bolts.
Hold the flywheel with an universal holder.
Remove the flywheel nut.
Universal Holder E017
Remove the A.C. generator flywheel using
the flywheel puller.
Flywheel Puller E001
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.
Special
Special
Cooling Fan
Universal Holder
Flywheel Puller
Bolts
Bolts
Bolts
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-10
Mongoose/KXR 90/50
A.C. GNERATOR INSTALLATION
Reverse the A.C. GENERATOR
REMOVE” procedures.
Install the A.C. generator stator and pulser
coil onto the right crankcase.
Install the A.C. generator wire rubber sleeve.
Tighten the stator and pulser coil bolts.
Torques: Pulser Coil : 0.45~0.6kgf-m
Stator: 0.8~1.2kgf-m
Connect the A.C. generator wire connector.
Clean the taper hole in the flywheel off any
burrs and dirt.
Install the woodruff key in the crankshaft
keyway.
Install the flywheel onto the crankshaft with
the flywheel hole aligned with the
crankshaft woodruff key.
A.C. Generator
Wire Rubber
Sleeve
Woodruff Key
Flywheel
Cooling Fan
Stator
3.5_ 4.5kgf-m
0.6_ 1.0kgf-m
The inside of the flywheel is magnetic.
Make sure that there is no bolt or nut
before installation.
＊
Woodruff Key
0.45_ 0.6kgf-m
Fan Cover
14. BATTERY/CHARGING SYSTEM/
A.C. GENERATOR
14-11
Mongoose/KXR 90/50
Hold the flywheel with the universal holder
and tighten the flywheel nut.
Torque: 3.5~4.5kgf-m
Universal Holder E017
Install the cooling fan.
Torque: 0.6~1.0kgf-m
Install the fan cover and tighten bolts.
Special
Loading...