FJR1300 AP 2010
Table of contents
Loading...
FJR1300AP
SUPPLEMENTARY MANUAL FOR POLICE VERSION
SUPPLEMENT AU MANUEL POUR LE MODELE DE POLICE
ERGÄNZENDE WARTUNGSANLEITUNG FÜR POLIZEI-MODELL
MANUALE SUPPLEMENTARE PER LA VERSIONE PER LA POLIZIA
MANUAL SUPLEMENTARIO PARA LA VERSIÓN DE POLICÍA
5P5-28199-52
SUPPLEMENTARY MANUAL FOR POLICE VERSION
SUPPLEMENT AU MANUEL POUR LE MODELE DE POLICE
ERGÄNZENDE WARTUNGSANLEITUNG FÜR POLIZEI-MODELL
MANUALE SUPPLEMENTARE PER LA VERSIONE PER LA POLIZIA
MANUAL SUPLEMENTARIO PARA LA VERSIÓN DE POLICÍA
WIRING DIAGRAM / SCHÉMA DE CÂBLAGE / SCHALTPLAN /
SCHEMA ELETTRICO / DIAGRAMA ELÉCTRICO
INTRODUCTION
This supplementary manual has been prepared to introduce new service and data for the
FJR1300AP. For complete information on service procedures, it is necessary to use this manual together with following manuals:
FJR1300A OWNER'S MANUAL (1CY-28199-E0, -F0, -G0, -H0, -S0)
FJR1300A SERVICE MANUAL (3P6-28197-E3, -F3, -G3, -H3, -S3)
FJR1300A ASSEMBLY MANUAL (3P6-28107-51)
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your vehicle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
FJR1300AP
SUPPLEMENTARY MANUAL
FOR POLICE VERSION
©2009 by Yamaha Motor Engineering Co., Ltd.
1st Edition, November 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Engineering Co., Ltd.
is expressly prohibited.
Printed in Japan
ILLUSTRATED SYMBOLS (Refer
to the illustration)
Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text.
1. With engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening
6. Specified value, Service limit
7. Resistance (Ω), Voltage (V), Electric current (A)
Illustrated symbols "8" to "13" in the exploded
diagrams indicate grade of lubricant and location of lubrication point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Apply brake fluid
11. Apply lightweight lithium-soap base grease
12. Apply molybdenum disulfide grease
13. Apply silicone grease
Illustrated symbols "14" to "15" in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
14. Apply locking agent (LOCTITE
15. Use new one
®
)
CONTENTS
DESCRIPTION.....................................................................................................1
SPECIFICATION LIST .................................................................................. 2
SPECIFICATIONS...............................................................................................3
INSTRUMENT AND CONTROL FUNCTIONS.................................................... 4
RIGHT HANDLEBAR SWITCHES ................................................................4
SEAT .............................................................................................................4
RADIO BOX...................................................................................................5
SUSPENSION............................................................................................... 5
TROUBLESHOOTING .................................................................................. 7
MAINTENANCE...................................................................................................8
SETUP PROCEDURES ................................................................................8
CABLE ROUTING DIAGRAM ..................................................................... 12
TROUBLESHOOTING ................................................................................ 21
CHECKING THE ELECTRICAL COMPONENTS .......................................22
TIGHTENING TORQUES............................................................................27
RECOMMENDED SPECIFICATIONS............................................................... 30
INTRODUCTION........................................................................................ 30
RECOMMENDED PARTS LIST................................................................. 30
SETUP PROCEDURES ............................................................................. 31
CABLE ROUTING DIAGRAM .................................................................... 34
DESCRIPTION
DESCRIPTION
1
2
3
1. Right handlebar switches
2. Seat
3. Radio box
1
SPECIFICATION LIST
DESCRIPTION
1
12
No. Part name
Front flashing
1
light bracket
2 Sub-battery — — — Standard
5P5B (EU-
ROPE)
Option Standard ←←
11
5P5C (F, B) 5P5D (AUS) 5P5E (ZA, ET)
2,3 4
10
9
5
8
6
7
Sub-battery
3
bracket
4 Radio box Option Standard ←←
Rear sub-wire
5
harness
Rear turn signal
6
light
Rear flashing
7
light stay
8 Tail cover FJR1300A spec Standard ←←
Saddlebag
9
guard
10 Rectifier Standard — — Standard
11 Engine guard Option — Standard ←
12
Front sub-wire
harness
Standard — Standard ←
Standard — Standard ←
Option — Standard ←
Option
Option Standard ←←
Standard
Standard (5P5C
spec)
Standard (5P5C
spec)
Standard ←
Standard ←
2
SPECIFICATIONS
Model name: FJR1300AP
Model code number: 5P5B (EUROPE)
5P5C (F, B)
5P5D (AUS)
5P5E (ZA, ET)
Dimensions:
Overall length 2230 mm
Overall width 740 mm
Overall height 1450 mm
Minimum ground clearance 130 mm
Weight:
With oil and fuel 291.0 kg
Front suspension:
Spring rate, K1 10.0 N/mm
SPECIFICATIONS
Rear suspension:
Soft
Spring rate, K1 95.4 N/mm
Spring rate, K2 130.2 N/mm
Hard
Spring rate, K1 130.2 N/mm
Enclosed gas/air pressure (STD) 1800 kPa
Sub-battery:
Model GT7B-4
Voltage, capacity 12 V, 6.5 Ah
Manufacturer GS YUASA
Ten hour rate amperage 0.65 A
Bulb voltage, wattage × quantity:
Rear turn signal light 12 V, 21.0 W × 2
Sub-battery relay:
Model/manufacturer ACM33211 M05/MATSUSHITA
Coil resistance 96.0 Ω
Flashing light and siren relay:
Model/manufacturer ACM33211 M05/MATSUSHITA
Coil resistance 96.0 Ω
Fuses:
CHARGE 30 A
DISCHARGE 20 A
PATROL 10 A
SUB 30 A
3
INSTRUMENT AND CONTROL FUNCTIONS
INSTRUMENT AND CONTROL
FUNCTIONS
RIGHT HANDLEBAR SWITCHES
PATROL SWITCH
Patrol switch "1" activates the siren or flashing
light.
It is used when a siren or flashing light is installed.
○ OFF
This is for the flashing light.
This is for both siren and flashing light.
1
SEAT
TO REMOVE THE SEAT
1. Insert the key into the seat lock, and then
turn it counterclockwise.
1. Seat lock
2. Unlock
2. Lift the rear of the seat and pull it off.
TO INSTALL THE SEAT
1. Insert the projection on the front of the seat
into the seat holder as shown, and then push
the rear of the seat down to lock it in place.
HAZARD SWITCH
With the key in the "ON" or "P" position, use
hazard switch "1" to turn on the hazard lights
(simultaneous flashing of all turn signal lights).
The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard.
Do not use the hazard lights for an extended
length of time with the engine not running,
otherwise the battery may discharge.
1
1. Projection
2. Seat holder
2. Remove the key.
Make sure that the seat is properly secured
before riding.
The seat height can be adjusted to change
the riding position.
4
INSTRUMENT AND CONTROL FUNCTIONS
RADIO BOX
The lid can be locked by turning the inserted
key "1".
1
a. LOCK
b. OPEN
Changeover of the position of the switch "2"
can prevent the sub-battery from being discharged.
ON:
When an auxiliary instruments are used.
OFF:
When no auxiliary instruments are used.
Do not turn the switch to "ON" when no auxiliary instruments are used, otherwise the
sub-battery may discharge.
a
b
Spring preload
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
Spring preload
a. Turn the adjusting bolt "1" in direction "a" or
"b".
Spring preload is in-
Direction "a"
Direction "b"
Spring preload adjusting positions
Standard
4
Minimum
6
Maximum
1
creased (suspension is
harder).
Spring preload is decreased (suspension is
softer).
2
ON
OFF
SUSPENSION
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
Securely support the vehicle so that there
is no danger of it falling over.
2. Current setting
5
INSTRUMENT AND CONTROL FUNCTIONS
Rebound damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Rebound damping
a. Turn the adjusting knob "1" in direction "a" or
"b".
Rebound damping is in-
Direction "a"
Direction "b"
Rebound damping adjusting positions
Standard
12 clicks out*
Minimum
17 clicks out*
Maximum
1 clicks out*
creased (suspension is
harder).
Rebound damping is decreased (suspension is
softer).
Compression damping
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Compression damping
a. Turn the adjusting screw "1" in direction "a"
or "b".
Compression damping is
Direction "a"
Direction "b"
Compression damping adjusting
positions
Standard
10 clicks out*
Minimum
21 clicks out*
Maximum
1 clicks out*
increased (suspension is
harder).
Compression damping is
decreased (suspension is
softer).
*: With the adjusting knob fully turned in
*: With the adjusting screw fully turned in
6
INSTRUMENT AND CONTROL FUNCTIONS
TROUBLESHOOTING
If the auxiliary instruments is not operating normally, perform the following procedures in the order
given.
Checking the auxiliary instruments
switch.
ON ↓
OFF → Turn the auxiliary instruments switch to "ON".
Checking the fuses.
OK ↓
Ask the mechanic to repair.
Remove the following parts before inspection.
1. Seat
Blown
fuse →
Replace the fuse.
7
MAINTENANCE
SETUP PROCEDURES
INSTALLING THE HANDLEBARS
MAINTENANCE
T
3.5 Nm
.R.
3
T
1.5 Nm
.R.
T
3.5 Nm
.R.
T
.R.
T
65 Nm
.R.
2 Nm
T
23 Nm
.R.
2
1
T
23 Nm
.R.
2
T
2 Nm
.R.
T
65 Nm
.R.
3
4
4
T
7 Nm
.R.
8
INSTALLING THE ENGINE GUARDS
T
64 Nm
.R.
2
T
.R.
3
7 Nm
2
3
4
T
7 Nm
.R.
A
MAINTENANCE
T
49 Nm
5
5
T
49 Nm
.R.
.R.
7
6
1
6
1
T
49 Nm
.R.
T
49 Nm
.R.
T
64 Nm
.R.
2
A
4
2
3
3
T
7 Nm
.R.
T
.R.
7 Nm
A. For installation of recommended parts
9
INSTALLING THE SADDLEBAG GUARDS
MAINTENANCE
T
29 Nm
.R.
4
4
T
.R.
4
29 Nm
T
10 Nm
.R.
5
T
10 Nm
.R.
T
25 Nm
.R.
6
T
1.5 Nm
.R.
6
T
1.5 Nm
.R.
5
3
T
28 Nm
.R.
1
1
T
25 Nm
.R.
3
2
T
9 Nm
.R.
2
T
9 Nm
.R.
1
T
28 Nm
.R.
1
10
INSTALLING THE RADIO BOX
T
.R.
7 Nm
T
.R.
3
2 Nm
MAINTENANCE
T
7 Nm
T
4 Nm
.R.
2
.R.
1
1
2
T
7 Nm
.R.
3
3
8
T
1 Nm
.R.
T
16 Nm
9
8
T
.R.
9
T
.R.
7 Nm
7
7 Nm
.R.
7
T
21 Nm
.R.
4
T
.R.
6
7 Nm
1
4
1
5
T
21 Nm
.R.
T
4 Nm
.R.
T
.R.
7 Nm
10
T
1 Nm
.R.
T
.R.
7 Nm
11
10
11
T
.R.
8 Nm
11
CABLE ROUTING DIAGRAM
MAINTENANCE
12
1. Right grip warmer lead
2. Right handlebar switch lead
3. Hazard switch lead
4. Front brake hose
5. Guide
6. Left handlebar switch lead
7. Left grip warmer lead
8. Clamp
9. Throttle cable (accelerator cable)
10. Throttle cable (decelerator cable)
A. Route the hazard switch lead, right handle-
bar switch lead and grip warmer lead under
the handlebar.
B. Route the hazard switch lead and grip
warmer lead over the right handlebar
switch lead while taking care not to have
them pinched between the guide and right
handlebar switch lead.
C. Route the left handlebar switch lead and
the grip warmer lead under the handlebar.
D. Pass the clutch hose, the handlebar switch
leads (left and right), the grip warmer leads
(left and right) and the hazard switch lead
through the guide.
E. Clamp the hazard switch lead and right
handlebar switch lead. Do not clamp the
grip warmer lead.
F. Clamp the hazard switch lead, right handle-
bar switch lead, grip warmer lead, main
switch lead and immobilizer unit lead.
G. Pass the front brake hose, the right handle-
bar switch lead, the right grip warmer lead,
the hazard switch lead, the throttle cable
through the guide.
H. Clamp the grip warmer lead on the throttle
cable. Fasten the clamp where 10 mm inside of the rubber boot end and cut off the
clamp end.
MAINTENANCE
13
MAINTENANCE
A-A
A
A
1. Extension wire lead
2. Wire lead (for battery charging)
3. Negative lead (for battery charging)
4. Coupler (for battery charging)
5. Fuse (SUB)
6. Clamp
7. Wire harness
8. Coupler (for speaker)
9. Negative battery lead
10. Starter motor lead
11. Stay
12. Wire harness assembly
13. Horn lead
14. Fan lead
15. Wire lead
A. Clamp the wire lead, the negative battery
lead, the starter motor lead on the battery
box. Clamp the wire lead on the white tape
marking section and turn the clamp end to-
ward the rear.
B. To the headlight lead
C. Remove the battery positive lead and con-
nect the sub-harness for recharge.
D. Clamp the wire harness assembly, nega-
tive battery lead and starter motor lead.
E. Route the wire harness assembly along the
front side of the frame and clamp the white
tape marking section of harness at the top
of the hole in the frame. Set the clamp end
inward without cutting it off.
14
MAINTENANCE
1. Right handlebar switch lead
2. Hazard switch lead
3. Grip warmer lead
4. Wire harness assembly
5. Clamp
6. Stay
7. Coupler (for siren)
8. Radiator hose
9. Coolant reservoir hose
10. Front wheel sensor lead
A. Connect the right handlebar switch lead to
the wire harness assembly.
B. Connect the hazard switch lead to the wire
harness assembly.
C. Clamp the handlebar switch lead, the grip
warmer lead and the hazard switch lead,
and pass them through the hole of the stay.
Set the clamp end downward without cutting it off.
D. Clamp the wire harness assembly, hazard
switch lead, handlebar switch lead and grip
warmer lead. Do not clamp the front wheel
sensor lead.
E. Clamp the handlebar switch lead, the grip
warmer lead, front wheel sensor lead and
the hazard switch lead, and pass them
through the hole of the stay. Set the clamp
end downward without cutting it off.
F. Route the wire harness assembly outside
the coolant reservoir hose and radiator
hose.
G. Route the wire harness assembly along the
front side of the frame and clamp the white
tape marking section of harness at the top
of the hole in the frame. Set the clamp end
inward without cutting it off.
15
MAINTENANCE
A
A
1. Wire harness assembly
2. Wire lead
3. Rear combination light lead
4. Rectifier/regulator
5. Rectifier
6. Clamp
7. Rectifier/regulator lead
8. Neutral switch lead
9. Main harness
10. Sub-lead wire
11. Rear frame
A. Connect the coupler having the wire lead
ID tape on it to the main harness.
B. Clamp the neutral switch lead, rectifier/reg-
ulator lead and sub-lead wire.
C. Route the sub-lead wire inside the main
harness.
D. Put the clamp tip on the inside of the frame.
E. Outside
A-A
F. Route the rear combination light lead on
the outside of the vehicle.
16
MAINTENANCE
B
U
S
1. Coupler (for battery charging)
2. Negative lead (for battery charging)
3. Fuse box
4. Extension wire lead
5. Air filter case
6. Insulator
7. Wire harness assembly
A. Route the wire lead through the clearance
between the battery and fuse box.
B. Install the fuse (SUB) in the inner fuse box
inserting it from underneath.
C. Align the white taped portion with the front
edge of the T-bar.
D. In installing the fuel tank, take care not to
have the extension wire lead pinched be-
tween the fuel tank and frame.
E. Route the extension wire lead along the
side of the air filter case.
F. Connect the connectors of the identical col-
or.
G. Route the wire harness assembly through
the hole in the frame to the left of the head
pipe and over the insulator.
17
A-A
MAINTENANCE
1. Fuel tank fitting bracket
2. Seat bracket
3. Sub-battery box
4. Relay
5. Coupler (for radio box)
6. Wire lead
7. Wire harness assembly
8. Sub-lead wire
9. Tool band
10. Fuse (PATROL)
11. Rear combination light lead
12. License plate light lead
13. Rear frame
14. Rear fender
A. Route the extension wire lead in the middle
under the tank fitting bracket and seat
bracket.
B. Route the wire lead along and over the rear
combination light lead.
A
A
C. Route the wire lead under the sub-battery
box.
D. Route the wire harness assembly outside
the sub-battery box.
E. Route the sub-lead wire inside the sub-bat-
tery box.
F. Connect the sub-lead wire to the wire har-
ness assembly. Place the coupler under
the wire harness assembly.
G. Connect the couplers of the identical color.
H. To the rectifier
I. To the relay
J. To the fuse
K. Insert the fuse (PATROL) into the stay.
L. The wiring within the radio box is shown in
the square.
M. Clamp the sub-lead wire and auxiliary in-
struments switch assembly lead.
18
MAINTENANCE
1. Fender
2. Box
3. Seat lock cable
4. Wire harness assembly
A. Route the seat lock cable between the
fender and the box, and pass it under the
box.
B. Route the seat lock cable under the wire
harness assembly.
19
MAINTENANCE
1. Coupler (for controller)
2. Coupler (for microphone)
3. Coupler (for front flashing light)
4. Headlight beam adjusting cable
5. Clamp
6. Wire harness assembly
7. Right handlebar switch lead
8. Identification red tape
A. Route the wire harness assembly at the
back of the headlight beam adjusting cable.
B. Route the wire harness assembly along the
bottom of the square pipe frame and clamp
it at the white tape. Direct the clamp end
downward.
C. Route the wire harness assembly just at
the head.
D. To the turn signal light and horn
E. To the main battery, including the speaker,
etc.
F. Connect the headlight lead and wire har-
ness assembly. (Connect the couplers of
the identical color.)
G. Fix the headlight cord and wire harness as-
sembly to the headlight mounting stay with
the clamp. Leave the clamp end to lie on
the inside of the cowling.
H. Route the clamp through the hole in the
stay and fix the wire harness assembly at
the white tape. Cut off the clamp end.
I. Route the wire harness assembly under
the stay.
J. To the extension wire lead under the fuel
tank
K. To the handlebar switch lead and siren
L. Clamp the wire harness assembly at the
white tape together with the headlight lead.
Direct the clamp end downward.
20
MAINTENANCE
TROUBLESHOOTING
If the auxiliary instruments is not operating normally, perform the following procedures in the order
given.
Checking the fuses.
OK ↓
Blown
fuse →
Replace the fuse.
Checking the wire harness connections.
OK ↓
Checking the patrol switch.
OK ↓
Checking the auxiliary instruments
switch.
OK ↓
Checking the sub-battery.
OK ↓
*Checking the auxiliary instruments.
(Refer to the instruction manual for the
auxiliary instruments.)
*marked: Not covered by warranty
Remove the following parts before inspection.
1. Seat
Use the following special tools in this inspection.
No good
→
No good
→
No good
→
No good
→
→ Please consult your Yamaha dealer.
Properly connect or repair the wire harness.
Replace the right handlebar switch.
Replace the auxiliary instruments switch.
Recharge or replace the sub-battery.
Pocket tester:
90890-03112
21
CHECKING THE ELECTRICAL COMPONENTS
CHECKING AND CHARGING THE SUBBATTERY
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical at-
tention.
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery
performance will deteriorate.
Charging time, charging amperage and
charging voltage for an VRLA (Valve Reg-
ulated Lead Acid) battery are different
from those of conventional batteries. The
VRLA (Valve Regulated Lead Acid) battery
should be charged as explained in the
charging method illustrations. If the bat-
tery is overcharged, the electrolyte level
will drop considerably. Therefore, take
special care when charging the battery.
MAINTENANCE
Since VRLA (Valve Regulated Lead Acid) batteries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by
measuring the voltage at the battery terminals.
1. Remove:
Seat
2. Disconnect:
Sub-battery leads
(from the sub-battery terminals)
First, disconnect the battery negative lead
"1", and then battery positive lead "2".
1
2
3. Remove:
Battery band
Sub-battery
4. Measure:
Battery charge
a. Connect a pocket tester to the battery termi-
nals.
Tester positive probe → battery positive
terminal
Tester negative probe → battery negative
terminal
The charge state of an VRLA (Valve Regulat-
ed Lead Acid) battery can be checked by
measuring its open-circuit voltage (i.e., the
voltage when the positive battery terminal is
disconnected).
No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.4 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
22
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
A. Relationship between the open-circuit
voltage and the charging time at 20 °C
(These values vary with the temperature,
the condition of the battery plates, and
the electrolyte level.)
B. Open-circuit voltage (V)
C. Charging time (hours)
D. Time (minutes)
E. Charging condition of the battery (%)
F. Ambient temperature 20 °C
a. Charging
b. Check the open-circuit voltage
5. Charge:
Sub-battery
(refer to the appropriate charging method illustration)
MAINTENANCE
Do not quick charge a battery.
Never remove the VRLA (Valve Regulated
Lead Acid) battery sealing caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause battery overheating and battery plate damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to re-
move it from the vehicle. (If charging has
to be done with the battery mounted on the
vehicle, disconnect the battery negative
lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate
heat in the contact area and a weak clip
spring may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process, disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
As shown in the following illustration, the
open-circuit voltage of an VRLA (Valve
Regulated Lead Acid) battery stabilizes
about 30 minutes after charging has been
completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
Charging method using a variable-current
(voltage) charger
a. Measure the open-circuit voltage prior to
charging.
23
Voltage should be measured 30 minutes after
the engine is stopped.
MAINTENANCE
c. Make sure that the current is higher than the
standard charging current written on the battery.
b. Connect a charged and ammeter to the bat-
tery and start charging.
Set the charging voltage at 16–17 V. If the setting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
c. Make sure that the current is higher than the
standard charging current written on the battery.
If the current is lower than the standard charging current written on the battery, set the charging voltage adjust dial at 20–24 V and monitor
the amperage for 3–5 minutes to check the battery.
Reach the standard charging current → Bat-
tery is good.
Does not reach the standard charging cur-
rent → Replace the sub-battery.
d. Adjust the voltage so that the current is at
the standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 minutes.
If the current is lower than the standard charging current written on the battery, this type of
battery charger cannot charge the VRLA (Valve
Regulated Lead Acid) battery. A variable voltage charger is recommended.
d. Charge the battery until the battery's charg-
ing voltage is 15 V.
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 minutes.
12.4 V or more --- Charging is complete.
12.3 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
6. Install:
Sub-battery
Battery band
7. Connect:
Sub-battery leads
(to the sub-battery terminals)
First, connect the battery positive lead "1",
and then the battery negative lead "2".
2
12.4 V or more --- Charging is complete.
12.3 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Charging method using a constant voltage
charger
a. Measure the open-circuit voltage prior to
charging.
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
1
8. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
Battery terminal
Recommended lubricant
Dielectric grease
10.Install:
Seat
24
Loading...