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Chapter 8 Part A Electrical system (XV535 models)
8A-3
1 General information
The machines covered by this manual are equipped with a 12-volt
electrical system.
The charging system on XV535 models uses a rotor with
permanent magnets that rotates around a stator coil of copper wire.
This produces alternating current, which is converted to direct current
by the regulator/rectifier. The regulator/rectifier also controls the
charging system output.
An electric starter mounted to the front of the engine is standard
equipment. The starter on early models has four brushes; the starter on
later models has two brushes. The starting system includes the motor,
the battery, the relay and the various wires and switches. If the engine
kill switch and the ignition (main key) switch are both in the On
position, the circuit relay allows the starter motor to operate only if the
transmission is in Neutral (Neutral switch on) or the clutch lever is
pulled to the handlebar (clutch switch on) and the sidestarfd is up
(sidestand switch on).
Note: Keep in mind that electrical parts, once purchased, can't be
returned. To avoid unnecessary expense, make very sure the faulty
component has been positively identified before buying a replacement
part.
2 Electrical troubleshooting
A typical electrical circuit consists of an electrical component, the
switches, relays, etc. related to that component and the wiring and
connectors that hook the component to both the battery and the
frame. To aid in locating a problem in any electrical circuit, complete
wiring diagrams of each model are included at the end of this Chapter.
Before tackling any troublesome electrical circuit, first study the
appropriate diagrams thoroughly to get a complete picture of what
makes up that individual circuit. Trouble spots, for instance, can often
be narrowed down by noting if other components related to that circuit
are operating properly or not. If several components or circuits fail at
one time, chances are the fault lies in the fuse or ground/earth
connection, as several circuits often are routed through the same fuse
and ground/earth connections.
Electrical problems often stem from simple causes, such as loose
or corroded connections or a blown fuse. Prior to any electrical
troubleshooting, always visually check the condition of the fuse, wires
and connections in the problem circuit. Intermittent failures can be
especially frustrating, since you can't always duplicate the failure when
it's convenient to test. In such situations, a good practice is to clean all
connections in the affected circuit, whether or not they appear to be
good. All of the connections and wires should also be wiggled to
check for looseness which can cause intermittent failure.
If testing instruments are going to be utilized, use the diagrams to
plan where you will make the necessary connections in order to
accurately pinpoint the trouble spot.
The basic tools needed for electrical troubleshooting include a
test light or voltmeter, a continuity tester (which includes a bulb,
battery and set of test leads) and a jumper wire, preferably with a
circuit breaker incorporated, which can be used to bypass electrical
components. Specific checks described later in this Chapter may also
require an ohmmeter.
Voltage checks should be performed if a circuit is not functioning
properly. Connect one lead of a test light or voltmeter to either the
negative battery terminal or a known good ground. Connect the other
lead to a connector in the circuit being tested, preferably nearest to the
battery or fuse. If the bulb lights, voltage is reaching that point, which
means the part of the circuit between that connector and the battery is
problem-free. Continue checking the remainder of the circuit in the
same manner. When you reach a point where no voltage is present, the
problem lies between there and the last good test point. Most of the
time the problem is due to a loose connection. Keep in mind that some
circuits only receive voltage when the ignition key is in the On position.
3.4 Always disconnect the negative battery cable first and
reconnect it last to prevent sparks which could cause the battery
to explode; be sure to reinstall the terminal covers for the
same reason
A Negative cable B Positive cable
One method of finding short circuits is to remove the fuse and
connect a test light or voltmeter in its place to the fuse terminals. There
should be no load in the circuit (it should be switched off). Move the
wiring harness from side-to-side while watching the test light. If the
bulb lights, there is a short to ground/earth somewhere in that area,
probably where insulation has rubbed off a wire. The same test can be
performed on other components in the circuit, including the switch.
A ground/earth,check should be done to see if a component is
grounded properly. Disconnect the battery and connect one lead of a
self-powered test light (continuity tester) to a known good ground.
Connect the other lead to the wire or ground/earth connection being
tested. If the bulb lights, the ground/earth is good. If the bulb does not
light, the ground/earth is not good.
A continuity check is performed to see if a circuit, section of
circuit or individual component is capable of passing electricity
through it. Disconnect the battery and connect one lead of a self-
powered test light (continuity tester) to one end of the circuit being
tested and the other lead to the other end of the circuit. If the bulb
lights, there is continuity, which means the circuit is passing electricity
through it properly. Switches can be checked in the same way.
Remember that all electrical circuits are designed to conduct
electricity from the battery, through the wires, switches, relays, etc. to
the electrical component (light bulb, motor, etc.). From there it is
directed to the frame (ground) where it is passed back to the battery.
Electrical problems are basically an interruption in the flow of electricity
from the battery or back to it.
3 Battery - inspection and maintenance
Refer to illustration 3.4
1 Most battery damage is caused by heat, vibration, and/or low
electrolyte levels, so make sure the battery is securely mounted, check
the electrolyte level frequently and make sure the charging system is
functioning properly.
2 Refer to Chapter 1 for electrolyte level aYid specific gravity
checking procedures.
3 Check around the base inside of the battery for sediment, which
is the result of sulfation caused by low electrolyte levels. These
deposits will cause internal short circuits, which can quickly discharge
the battery. Look for cracks in the case and replace the battery if
either of these conditions is found.
4 Check the battery terminals and cable ends for tightness and
corrosion. If corrosion is evident, remove the cables from the battery
(see illustration) and clean the terminals and cable ends with a wire
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