Kymco MO P50 Service Manual - chap 15 (imp elettrico)

15. ELECTRICAL EQUIPMENT

15-0

15

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ELECTRICAL EQUIPMENT

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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

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

BA10AB.AC.

Capacity

12V4AH

Voltage

13.0_ 13.2V

Charging

Standard

0.4A/5H

Battery

current

Quick

4A/0.5H

Spark plug

(NGK)

BR8HSA

Spark plug gap

0.6_ 0.7mm

Primary coil

0.2_ 0.3W

Secondary coil
(with plug cap)

7.0_ 8.4KW

Ignition coil resistance

Secondary coil
(without plug cap)

2.5_ 3.2KW

Pulser coil resistance (20℃ )

80_ 160W

Ignition timing

8°~14°±1.5°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 sy stem

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

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 coil

óBetween A.C. generator and CDI unit óPoorly connected wire or connector
óBetween CDI unit and ignition coil • Ignition secondary circuit
óBetween CDI unit and ignition switch óFaulty ignition coil
óBetween 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

CHARGING SYSTEM

A.C. Generator

Dimmer Switch

Headlight Switch

Ignition Switch

Resistor

Battery

Y

W

5. 9W
30W

Wire Harness B

GRWGR

YYY

Auto
Bystarter

Fuse

Regulator/
Rectifier

Ignition Switch

G/B

Resistor

Resistor

A.C. Generator

Pulser Coil

10.2W
5W

L/Y

G/B

15. ELECTRICAL EQUIPMENT

15-4

BATTERY

BATTERY REMOVAL

Remove the front tool box cover.
Disconnect the battery cables .

Remove the bolt and battery bracket.
Remove the battery.
The installation sequence is the reverse of
removal.

BATTERY CHARGING (OPEN CIRCUIT
VOLTAGE) INSPECTION

Remove the battery cover and disconnect
the battery cables.
Measure the voltage between the battery
terminals.
Fully charged : 13.0V_ 13.2V
Undercharged : 12.3V max.

CHARGING METHOD

Connect the charger positive (+) cable to
the battery positive (+) cable.
Connect the charger negative (-) cable to the
battery negative (-) cable.

Charging current : Standard : 0.4A

Quick : 4A

Charging time : Standard : 5 hours

Quick : 0.5 HOUR

After charging: Op en circuit voltage: 12.8V min.

Front tool box Cover

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

＊

Battery charging inspection must be
performed with an electric tester.

＊

• Quick charging should only be done in

an emergency.

• During quick charging, the battery

temperature should not exceed
45℃ .

• Measure the voltage 30 minutes after

the battery is charged.

＊

• 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.

• Charge the battery according to

the current specified on the battery
surface.

＊

Power

Lamp

(Green)

Red

Black

Charging

Lamp
(Red)

Battery

15. ELECTRICAL EQUIPMENT

15-5

PERFORMANCE TEST

Warm up the engine.
Remove the floor mat and front tool box
cover.

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

Position

RPM

Day

Night

2500

1.3A min.

1.0A min.

6000

2.0A min.

2.0A min.

Charging Limit Voltage: 14.5±0.5V/8000rpm
If the limit voltage is not within the

specified range, check the regulator/
rectifier.

A.C. GENERATOR (CHARGING
COIL) INSPECTION

Remove the met-in box. (!12-4)
Disconnect the A.C. generator connector.
Measure the resistances between the
charging coil terminals (whiteñgreen) and
lighting coil terminals (yellowñgreen).

Resistances:

Charging coil

whiteñgreen

0.2_ 1.2

W

Lighting coil

yellowñgreen

0.3_ 1.0

W

Refer to 7-3 for A.C. generator removal.

A.C. Generator Connector

Use a fully charged battery to check the
charging system output.

＊

Inspect with the engine installed.

＊

15. ELECTRICAL EQUIPMENT

15-6

RESISTOR INSPECTION

Remove the frame front cover. (!12-3)
Measure the resistance between the resistor
B pink wire and ground.
Measure the resistance between the resistor
A green/black wire and ground.

Resistances:

Resistor A: 9.9_ 12.0W
Resistor B: 5.6_ 7.2W

REGULATOR/RECTIFIER
INSPECTION

Remove the front cover. (!12-3)
Disconnect the regulator/rectifier wire
coupler and remove the bolt to remove the
regulator/rectifier.

Measure the resistances between the
terminals.
Replace the regulator/rectifier if the readings
are not within the specifications in the table
below.

Model

Brand

Range

SP-10D

Sanwa

KW

TH-5H

Kowa

100W

Probe⊕

Probe(-)

A (R)

B (W)

C (Y)

D (G)

A (R)

20-

35KW

∞

∞

B (W)

8-20KW

∞

∞

C (Y)

∞∞∞

D (G)

∞

∞

6.5-35KW

• Due to the semiconductor in circuit, it

is necessary to use a specified tester
for accurate testing. Use of an
improper tester in an improper range
may give false readings.

• Use a Sanwa Electric Tester (07208-

0020000) or Kowa Electric Tester
(TH-5H). The proper range for
testing is listed below.

＊

Coupler

Faulty resistor is the cause of faulty
operation of the auto bystarter.

＊

A (Red)

C (Yellow)

D (Green)

B (White)

Resister A

Resister B

Regulator/Rectifier

Bolt

15. ELECTRICAL EQUIPMENT

15-7

Ignition Coil

Pulser Coil

Ignition Switch

Spark Plug

A.C. Generator (Exciter Coil)

A.C. Generator

R

CDI Unit

Ignition
Switch

Spark
Plug

G

YBG

Battery

Fuse
7A

Regulator/
Rectifier

W

B

W

GRY

Pulser Coil

L/Y

Ignition Coil

B/Y

B/Y

L/Y

G

G

15. ELECTRICAL EQUIPMENT

15-8

IGNITION COIL INSPECTION
Continuity Test

Remove the met-in box. (!12-4)
Measure the resistance between the ignition
coil primary coil terminals.

Resistance (20℃ ): 0.153_ 0.187W

Measure the secondary coil resistance
between the spark plug cap and the primary
coil terminal as Figure A shown.

Resistance (20℃ ) (with plug cap):

7.0_ 8.4KW

Measure the secondary coil resistance
between the ignition coil terminal and the
primary coil terminal as Figure B shown.
Resistance (20℃ ) (without p lug cap):

2.5_ 3.2KW

This test is to inspect the continuity of
ignition coil.

＊

Figure A

Figure B

Ignition Coil

Green

Black

15. ELECTRICAL EQUIPMENT

15-9

Performance Test

Remove the ignition coil.

Inspect the ignition coil with an ignition coil
tester.

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

2. Turn the power switch ON and check the
spark 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 wire
connector.
Measure the pulser coil resistance between
the blue/yellow wire and ground.

Resistance (20℃ ): 100_ 150W

This test is performed with the stator
installed in the engine.

＊

Follow the ignition coil tester manufac­turer‘s instructions.

＊

Ignition Coil

AC 110V

6V/12V
Changeover
Switch

Ignition Coil Tester
07508-0070100

Watch Window

Black

Black(-)

Red(+)

Black(-)

Red(+)

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

＊

Blue/Yellow

15. ELECTRICAL EQUIPMENT

15-10

CDI UNIT INSPECTION

Remove the battery cover.
Disconnect the CDI coupler and remove the
CDI unit.

CDI CIRCUIT INSPECTION

Measure the resistance between the
terminals.
Replace the CDI unit if the readings are not
within 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: KW

Probe⊕

(-)Probe

Black

Blue/

Yellow

Green

Black/

Yellow

Black

∞

13~16

∞

Blue/

Yellow

33

~

40

18~22

∞

Green

8

~

10

∞

∞

Black/

Yellow

14~17

∞

2.5~3.0

• Due to the semiconductor in circuit, it is

necessary to use a specified tester for
accurate testing. Use of an improper
tester in an improper range may give
false readings.

• Use a Sanwa Electric Tester or Kowa

Electric Tester (TH-5H).

• In this table, “Needle swings then

returns” indicates that there is a charging
current applied to a condenser. The needle
will then remain at “∞ ” unless the
condenser is discharged.

＊

CDI Unit

Blue/ Yellow
Green

Black

Black/ Yellow

Coupler

15. ELECTRICAL EQUIPMENT

15-11

Starter Button

Starter Motor

Ignition Switch

G

G/Y

Ignition Switch

Fuse
7A

Stop Switch

R

G/Y

Y/R

R/W

Front

Rear

Starter Button

Battery

Starter Motor

Stoplight

Starter Relay

15. ELECTRICAL EQUIPMENT

15-12

STARTER RELAY INSPECTION

Remove the front cover.
Disconnect the starter relay coupler and
then remove the starter relay.

Connect the starter relay green/yellow
terminal to the 12V battery positive (+)
terminal and the relay yellow/red terminal
to the battery negative (-) terminal. Check
for continuity between the starter relay red
and red/white terminals. The relay is
normal if there is continuity.

STARTER MOTOR REMOVAL

Disconnect the starter motor cable.
Remove the two bolts attaching the starter
motor and remove the starter motor.
The installation sequence is the reverse of
removal.

Starter Relay

Green/Yellow

Starter Motor

Red/White

Bolts

Yellow/Red

Red

15. ELECTRICAL EQUIPMENT

15-13

STARTER MOTOR INSPECTION

Connect a battery across the starter motor
and check for its operation.

1. Do not turn the starter motor for a
long time.

2. This inspection should be done with a
fully charged battery.

＊

Battery

Starter Motor

Battery (+) Terminal