Kymco MO X500 Service Manual - chap 17 (imp ricarica)

17. BATTERY/CHARGING SYSTEM

XCITING 500

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BATTERY/CHARGING SYSTEM

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CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1

SERVICE INFORMATION------------------------------------------------ 17-2

TROUBLESHOOTING----------------------------------------------------- 17-4

BATTERY -------------------------------------------------------------------- 17-5

CHARGING SYSTEM INSPECTION ----------------------------------- 17-6

ALTERNATOR CHARGING COIL-------------------------------------- 17-7

REGULATOR/RECTIFIER------------------------------------------------ 17-8

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17. BATTERY/CHARGING SYSTEM

CHARGING SYSTEM LAYOUT

XCITING 500

CHARGING CIRCUIT

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17. BATTERY/CHARGING SYSTEM

XCITING 500

SERVICE INFORMATION

GENERAL

CAUTION

• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide
adequate ventilation when charging.

• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe
burns. Wear protective clothing and a face shield.

─ If electrolyte gets on your skin, flush with water.

─ If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician

immediately.

• Electrolyte is poisonous.

─ If swallowed, drink large quantities of water or milk and call your local Poison Control

Center or physician immediately, KEEP OUT OF REACH OF CHILDREN.

• Always turn off the ignition switch before disconnecting any electrical component.

• Some electrical components may be damaged if terminals or connectors are connected or

disconnected while the ignition switch is turned to “ON” and current is present.

• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.

• For a battery remaining in a shorted vehicle, disconnect the negative battery cable from the battery.

• The battery caps should not be removed. Attempting to remove the sealing caps from the cells

may damage the battery.

• The maintenance free battery must be replaced when it reaches the end of its service life.

• The battery can be damaged if overcharged or undercharged, or if left to discharge for long

period. These same conditions contribute to shortening the “life span” of the battery. Even under
normal use, the performance of the battery deteriorates after 2-3 years.

• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will
drop quickly and eventually die out. For this reason, the charging system is often suspected as the
problem. Battery overcharge often results from problems in the battery itself, which may appear
to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not
increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the
electrolyte level goes down quickly.

• Before troubleshooting the charging system, check for proper use and maintenance of the battery.
Check if the battery is frequently under heavy load, such as having the headlight and taillight on
for long periods of time without riding the vehicle.

• The battery self-discharge when the vehicle is not in use, for this reason, charge the battery every
2 weeks to prevent sulfate from occurring.

• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its
maximum performance, always charge the battery. Also, the battery life is lengthened when it is
initially charged.

• When checking the charging system, always follow the steps in the troubleshooting flow chart
(page 17-4)

• For alternator service, refer to section 12

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17. BATTERY/CHARGING SYSTEM

BATTERY CHARGING

• This model comes with a maintenance free (MF) battery. Remember the following about MF
batteries.

─ Use only the electrolyte that comes with the battery.
─ Use all of the electrolyte
─ Seal the battery properly
─ Never open the seals again

• For battery charging, do not exceed the charging current and time specified on the battery. Using
excessive current or extending the charging time may damage the battery.

SPECIFICATIONS

ITEM SPECIFICATIONS

Battery

Capacity 12V – 12 Ah
Current leakage 0.5 Ma max.

Full charged 13.0 – 13.2 VVoltage (20°C/68°F)
Needs charging Below 12.3 V

Charging current

Capacity 240 W/5000 rpmAlternator
Charging coil resistance (20°C/68°F) 0.1 – 0.5Ω

Normal 1.4 A/5 – 10 h
Quick 5.5 A/0.5 h

XCITING 500

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17. BATTERY/CHARGING SYSTEM

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TROUBLESHOOTING

Battery is damaged or weak

XCITING 500

Remove the battery.
Check the battery condition.

Correct

Install the battery.
Check the battery current leakage.

Specified current leakage: 0.5 Ma
max

Correct

Check the alternator charging coil.

Standard: 0.1 – 0.5 Ω (20°C/68°F)

Correct

Incorrect

Incorrect

Incorrect

•Faulty battery

Disconnect the regulator/rectifie
connectors and recheck the battery
current leakage.

Incorrect

•Faulty regulator/rectifier.

•Shorted wire harness.

•Faulty ignition switch.

•Faulty charging coil.

Correct

Measure and record the battery
voltage using a digital multimeter.
Start the engine.
Measure the charging voltage.
Compare the measurements to result
of the following calculation.

Measured voltage < measured
charging voltage < 15.5 V

Incorrect

Perform the regulator/rectifier wire
harness inspection.

Correct

•Faulty regulator/rectifier

Correct

Incorrect

•Faulty battery.

•Open circuit in related wire.

•Loose or poor contacts of related

terminal.

•Shorted wire harness

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17. BATTERY/CHARGING SYSTEM

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XCITING 500

BATTERY

REMOVAL/INSTALLATION

Unlock and open the seat (page 2-3).
Turn ignition switch OFF.
Remove the screws and battery box cover.

Remove the battery retainer.
With the ignition switch to “OFF” disconnect

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

Pull out the battery from the battery box.

Screws

Battery Box Cove

Positive Terminal Negative Terminal

Installation is in the reverse order of removal.

After connecting the battery cables, coat the
terminals with grease.

VOLTAGE INSPECTION

Remove the battery cover (see above).

Measure the battery voltage using a
commercially available digital multimeter.

Voltage (20ºC/68ºC):

Fully charged: 13.0－13.2 V
Under charged: below 12.3 V

Battery Battery Retaine

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17. BATTERY/CHARGING SYSTEM

BATTERY CHARGING

Remove the battery (page 17-5).

Connect the charger positive (+) cable to the
battery positive (+) terminal.

Connect the charger negative (-) cable to the
battery negative (-) terminal.

＊

Turn the power ON/OFF at the chatger,
not at the battery terminals.

Charging current time:

Standard: 1.4 A/5－10 hours
Quick: 5.5 A/0.5 hours

Quick charging should only be done in an
emergency; slow charging is preferred.
For battery charging, do not exceed the
charging current and time specified on the
battery. Using excessive current or extending
the charging time may damage the battery.

XCITING 500

CHARGING SYSTEM
INSPECTION

Remove the battery cover (page 17-5).

CURRENT LEAKAGE TEST

Turn the ignition switch OFF, 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: 0.5 Ma max.

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.

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17. BATTERY/CHARGING SYSTEM

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CHARGING VOLTAGE INSPECTION

Be sure that the battery is in good condition
before performing this test.

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Do not disconnect the battery or any
cable in the charging system without first
switching off the ignition switch. Failure
to follow this precaution can damage the
tester or electrical components.

Start the engine and warm it up to the
operating temperature; stop the engine.

Connect the multimeter between the positive
and negative terminals of the battery.

To prevent short, make absolutely certain
which are the positive and negative terminals
or cable.

With the headlight on and turned to the high
beam position, restart the engine.

Measure the voltage on the multimeter when
the engine runs at 5000 min-1 (rpm).

XCITING 500

Standard:
Measured battery voltage (page 17-5) <

Measure charging voltage (see above)
<15.5 V

ALTERNATOR CHARGING COIL

INSPECTION

Remove the luggage box (page 2-3).

Disconnect the alternator connector.

Alternator Connecto

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17. BATTERY/CHARGING SYSTEM

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XCITING 500

Measure the resistance between each Yellow
wire terminals.

Standard: 0.1－0.5 Ω (20ºC/68ºF)

Check for continuity between each Yellow
wire terminal of the alternator side connector
and ground.

There should be continuity.

Replace the alternator stator if resistance is
out of specification, or if any wire has
continuity to ground.

Refer to section 12 for alternator stator
replacement.

REGULATOR/RECTIFIER

WIRE HARNESS INSPECTION

Remove the luggage box (page 2-3).

Alternator Connecto

Regulator/Rectifie

Disconnect the regulator/rectifier connectors.
Check the connectors for loose contacts of

corroded terminals.

Battery line

Measure the voltage between the Red/White
wire terminal and ground.

There should be battery voltage at all times.

Regulator/Rectifier Connectors

Regulator/Rectifier Connecto

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17. BATTERY/CHARGING SYSTEM

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XCITING 500

Ground line

Check the continuity between the Green wire
terminal and ground.

There should be continuity at all times.

Charging coil line

Measure the resistance between each Yellow
wire terminals.

Standard: 0.1－0.5 Ω (20ºC/68ºF)

Regulator/Rectifier Connecto

Check for continuity between each Yellow
wire terminal and ground.

There should be no continuity.

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Regulator/Rectifier Connecto

Regulator/Rectifier Connecto

Regulator/Rectifier Connecto

17. BATTERY/CHARGING SYSTEM

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XCITING 500

REMOVAL/INSTALLATION

Remove the side body cover (page 2-8).

Disconnect the regulator/rectifier connectors.

Remove the two bolts, regulator/rectifier and
stay.

Installation is in the reverse order of removal.

Regulator/Rectifier Connecto

Bolts

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