13. Electrical System
13-2
Precautions in Operation
Charging system
• When removing the battery, the disconnection sequence of cable terminals shall be strictly
observed. (First disconnect the negative cable terminal then the positive cable terminal.)
• The electrolyte level should be checked carefully. Add distilled water if electrolyte is not
enough.
• Remove the battery from the frame before charging and remove the electrolyte plug from the
battery.
• Do not proceed with quick charging except in emergency.
• The voltage meter is required when checking the charging voltage.
• The battery can be recharged. If the battery is not in use after being discharged, it will lead to
damage, short life span or lower performance. The performance of the battery may decline
after 1-2 years of normal usage. The voltage of the battery with lower capacity will recover after
recharging.
• If the battery cells are shorted, the terminal voltage cannot be measured. When the regulator
rectifier doesn’t function properly, the charging voltage will be too excessive and the battery life
span will be shortened.
• The battery will self discharge if the battery is not in use for a long period of time. Recharge the
battery two months later when the vehicle is not in use.
• Add electrolyte to the new battery and ten minutes later check if the terminal voltage is over
12.5V or not. Recharge the battery if the terminal voltage is too low. Charging the new battery
before using it may lengthen the battery life span.
• Follow the troubleshooting procedure to check the charging system.
• Always turn off the main switch before disconnecting any electrical components or the
regulator rectifier will be damaged due to excessively high voltage.
• Follow the removal procedure to remove the AC Generator and pulse coil.
Ignition system
• Follow the troubleshooting procedure to check the ignition system.
• The ignition timing does not need to be adjusted since the C.D.I. is factory present. Check the
C.D.I and AC Generator if the ignition timing is not correct. Check the ignition timing with
ignition timing light after replacement.
• The drooping or impact of C.D.I. set may lead to malfunction. Pay attention during removal.
• Most of the malfunctions result from poor contact of terminal, coupler and switch. Check for
any poor contact before proceeding with repair or maintenance.
• Improper spark plug will cause abnormal operation or severe damage of engine. Besides, pay
attention to the spark plug tightening torque.
Starting system
• Follow the troubleshooting procedure to check the starting system.
• The removal of the starter motor can be preceded when the engine is still on the vehicle.
• Refer to chapter 5 to remove the starter clutch.
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