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    Agility 125 Section 14 Battery Charging System AC Generator PDF

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    dabura1986
    The document describes the battery, charging system, and A.C. generator for a motorcycle. It includes specifications, component locations, testing procedures, and troubleshooting steps. The charging system uses a regulator/rectifier to control voltage from the A.C. generator to the battery. Testing involves checking voltages and resistances to diagnose issues like low power, intermittent power, or charging system failure.

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    © All Rights Reserved
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    Agility 125 Section 14 Battery Charging System AC Generator PDF

    Uploaded by

    dabura1986
    239 views11 pages
    The document describes the battery, charging system, and A.C. generator for a motorcycle. It includes specifications, component locations, testing procedures, and troubleshooting steps. The charging system uses a regulator/rectifier to control voltage from the A.C. generator to the battery. Testing involves checking voltages and resistances to diagnose issues like low power, intermittent power, or charging system failure.

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    Agility 125 Section 14 Battery Charging System AC Generator.pdf

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    The document describes the battery, charging system, and A.C. generator for a motorcycle. It includes specifications, component locations, testing procedures, and troubleshooting steps. The charging system uses a regulator/rectifier to control voltage from the A.C. generator to the battery. Testing involves checking voltages and resistances to diagnose issues like low power, intermittent power, or charging system failure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    239 views11 pages

    Agility 125 Section 14 Battery Charging System AC Generator PDF

    Uploaded by

    dabura1986
    The document describes the battery, charging system, and A.C. generator for a motorcycle. It includes specifications, component locations, testing procedures, and troubleshooting steps. The charging system uses a regulator/rectifier to control voltage from the A.C. generator to the battery. Testing involves checking voltages and resistances to diagnose issues like low power, intermittent power, or charging system failure.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 11

    14.

    BATTERY/CHARGING SYSTEM/
    A.C. GENERATOR

    14

    Battery

    AGILITY 125

    Fuse

    Regulator/Rectifier

    CDI

    Resistors
    A.C. Generator

    Headlight Switch

    Auto
    Bystarter

    Resistor

    A.C. Generator

    G Y W R

    G/B

    5
    5W

    14

    Regulator/
    Rectifier
    Battery
    12V4AH

    14-0

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGIKITY 125

    SERVICE INFORMATION...................... 14-1 A.C. GENERATOR CHARGING COIL ...14-6


    TROUBLESHOOTING ............................ 14-2 RESISTOR INSPECTION........................14-6
    BATTERY................................................. 14-3 A.C. GENERATOR REMOVAL .............14-6
    CHARGING SYSTEM ............................. 14-4 A.C. GENERATOR INATALLATION ...14-8
    REGULATOR/RECTIFIER...................... 14-5

    SERVICE INFORMATION
    GENERAL INSTRUCTIONS
    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
    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 23 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 wont 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.

    14-1

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGILITY 125

    SPECIFICATIONS
    Standard

    Item
    Battery

    A.C. Generator

    Regulator/Rectifier

    Capacity/Model
    Voltage
    Fully charged
    (20)
    Undercharged
    Charging current
    Charging time
    Capacity
    Lighting coil resistance (20)
    Charging coil resistance (20)
    Type
    Limit voltage

    Lighting

    Charging
    Resistor

    Resistance (20)
    Resistance (20)

    TORQUE VALUES
    Pulser coil bolt
    Stator bolt
    Flywheel nut
    Cooling fan bolt

    12V7AH
    13.1V
    12.3V
    STD: 0.4A Quick: 4.0A
    STD: 510hr Quick: 30min
    0.144KW/5000rpm
    YellowGreen
    0.11.0
    WhiteGreen
    0.21.2

    Single-phase half-wave SCR


    13.113.9V/5000rpm (Electric tester, tachometer)
    13.10.5V
    14.50.5V/5000rpm
    5W12
    30W7.5

    0.45~0.6kgf-m
    0.8~1.2kgf-m
    3.5~4.5kgf-m
    0.8~1.2kgf-m

    SPECIAL TOOLS
    Universal holder
    Flywheel puller
    TESTING INSTRUMENTS
    Kowa electric tester
    Sanwa electric tester

    TROUBLESHOOTING
    No power
    Dead battery
    Disconnected battery cable
    Fuse burned out
    Faulty ignition switch

    Intermittent power
    Loose battery cable connection
    Loose charging system connection
    Loose connection or short circuit in
    lighting system

    Low power
    Weak battery
    Loose battery connection
    Charging system failure
    Faulty regulator/rectifier

    Charging system failure


    Loose, broken or shorted wire or connector
    Faulty regulator/rectifier
    Faulty A.C. generator

    14-2

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    BATTERY

    AGIKITY 125
    Battery Cover

    REMOVAL
    Remove the battery cover screws on the floor
    board.
    Open the battery cover and remove the
    battery by removing the bolt and band.
    First disconnect the battery negative (-) cable
    and then the positive (+) cable.
    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.
    battery

    The installation sequence is the reverse of


    removal.
    First connect the positive (+) cable and the
    negative (-) cable to avoid short circuit.
    BATTERY VOLTAGE (OPEN CIRCUIT
    VOLTAGE) INSPECTION
    Remove the floor board.
    Open the battery cover and disconnect the
    battery cables.
    Measure the voltage between the battery
    terminals.
    Fully charged : 13.1V
    Undercharged : 12.3V max.

    Battery charging inspection must be

    negative (-) cable

    positive (+) cable

    performed with a voltmeter.


    CHARGING
    Connect the charger positive (+) cable to the
    battery positive (+) terminal.
    Connect the charger negative (-) cable to the
    battery negative (-) terminal.
    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 the
    t
    ifi d
    th b tt
    Quick charging should only be done in
    an emergency.
    Measure the voltage 30 minutes after
    the battery is charged.
    Charging current: Standard : 0.4A
    Quick : 4A
    Charging time : Standard : 510 hours
    Quick : 30 minutes
    After charging: Open circuit voltage: 12.8V min.
    Note: The battery temperature should not
    exceed 45during charging.

    14-3

    Red
    Black

    Power Lamp (Red)


    Charging Lamp (Green)

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGILITY 125

    CHARGING SYSTEM

    Terminal

    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.

    Connect the electric tester positive (+)


    terminal to ground wire and the tester
    negative (-) terminal to the battery
    negative (-) terminal.

    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 fuse and connect an
    ammeter between the fuse terminals.
    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: 1415V/0.5A max.
    (5000rpm max.)
    If the limit voltage is not within the specified
    range, check the regulator/rectifier. (14-5)

    Battery
    (-) Terminal

    (+) Terminal

    fuse
    Headlight Wire Coupler

    LIGHTING SYSTEM LIMIT VOLTAGE


    INSPECTION
    Remove the handlebar front cover. (2-2)

    Measure the voltage with the electric


    tester in the AC range.

    Limit Voltage: 1214V/ (5000rpm max.)


    If the limit voltage is not within the specified
    range, check the regulator/rectifier. (14-5)

    Perform this test with a fully charged


    battery.

    14-4

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    REGULATOR/RECTIFIER

    AGIKITY 125
    Regulator/Rectifier

    MAIN HARNESS CIRCUIT INSPECTION


    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)
    Between battery (red)
    and engine ground
    Between ground (green)
    and engine ground
    Between lighting wire
    (yellow) and engine
    ground (Remove the
    resistor coupler and auto
    bystarter coupler and
    turn the lighting switch
    OFF for inspection)
    Between charging coil
    (white) and engine
    ground

    Judgment
    Battery has
    voltage
    Continuity exists

    A.C. generator
    stator has
    resistance
    A.C. generator
    stator has
    resistance

    Red

    Yellow

    REGULATOR/RECTIFIER INSPECTION
    If the main harness terminals are normal,
    check the regulator/rectifier coupler for loose
    connection and measure the resistances
    between the regulator/rectifier terminals.

    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.
    Kowa Electric Tester
    Sanwa Electric Tester
    Kowa Electric Tester TH-5H
    Proper range for testing:
    Use XK range for Sanwa Tester
    Use X100 range for Kowa Tester
    If the dry battery in the tester is weak,
    the readings will be incorrect. In this
    case, check the dry battery.
    The Kowa tester readings are 100
    times the actual values. Be careful
    during testing.
    Replace the regulator/rectifier if the readings
    are not within the specifications in the table.

    14-5

    White
    Probe
    Probe(-)

    Green

    White Yellow Red


    Green
    White

    3K-50K

    Yellow

    5K-100K
    Red

    Green

    5K-50K

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    A.C. GENERATOR CHARGING


    COIL

    AGILITY 125
    Charging Coil Wire

    The inspection of A.C. generator charging


    coil can be made with the engine installed.
    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.
    Standard: 0.21.2(at 20)
    Replace the A.C. generator charging coil if
    the reading is not within the specifications.

    A.C. GENERATOR LIGHTING


    COIL

    The inspection of A.C. generator lighting


    coil can be made with the engine installed.
    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.
    Standard: 0.11.0 (20)
    Replace the A.C. generator lighting coil if the
    reading is not within the specifications.

    Lighting Coil Wire

    RESISTOR INSPECTION
    Remove the front covers. (2-2)
    Measure the resistance between the resistor
    lead and engine ground.
    Resistances: 5W12: 1113
    30W7.5: 68

    Resistor

    A.C. GENERATOR
    REMOVAL
    Remove the right side cover. (2-4)
    Remove the four bolts attaching the cooling
    fan cover to remove the fan cover.

    Fan Cover

    14-6

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGIKITY 125

    Remove the cooling fan by removing the four


    cooling fan attaching bolts.

    Cooling Fan

    Hold the flywheel with an universal holder.


    Remove the flywheel nut.

    Universal Holder

    Special

    Universal Holder

    Remove the A.C. generator flywheel using


    the flywheel puller.
    Remove the woodruff key.
    Special

    Flywheel Puller

    Flywheel Puller
    A.C. Generator Wire Connector

    Remove the A.C. generator wire connector.

    14-7

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGILITY 125
    Bolts

    Remove the A.C. generator wire set plate.


    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.

    Bolts

    A.C. GNERATOR INSTALLATION


    Flywheel
    Woodruff Key

    5.5kg-m
    Cooling Fan

    0.9kg-m

    Fan Cover

    0.5kg-m

    A.C. Generator Wire


    Rubber Sleeve

    Stator

    Install the A.C. generator stator and pulser


    coil onto the right crankcase.
    Tighten the stator and pulser coil bolts.
    Torques: Pulser Coil : 0.45~0.6kgf-m
    Stator
    : 0.8~1.2kgf-m

    Bolts

    Bolts

    Install the A.C. generator wire rubber sleeve


    and A.C. generator wire set plate.

    14-8

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    Connect the A.C. generator wire connector.

    AGIKITY 125
    A.C. Generator Wire Connector

    Woodruff Key

    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.

    Universal Holder

    The inside of the flywheel is magnetic.


    Make sure that there is no bolt or nut
    before installation.

    Hold the flywheel with the universal holder


    and tighten the flywheel nut.
    Torque: 3.5~4.5kgf-m

    Special

    Universal Holder
    Install the cooling fan.
    Torque: 0.8~1.2kgf-m

    14-9

    Cooling Fan

    14. BATTERY/CHARGING SYSTEM/


    A.C. GENERATOR

    AGILITY 125

    Install the fan cover.


    Install the right side cover. (2-4)

    Fan Cover

    14-10

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