How to Troubleshoot, Repair, and Modify Motorcycle Electrical Systems (Motorbooks Workshop)

211 Pages·22.328 MB·English

by  Tracy Martin

HOW TO TROUBLESHOOT, REPAIR, AND MODIFY
MOTORCYCLE
ELECTRICAL SYSTEMS
By Tracy Martin
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First published in 2014 by Motorbooks, an imprint of About the Author
Quarto Publishing Group USA Inc., 400 First Avenue Tracy Martin writes for Motorcycle Consumer News,
North, Suite 400, Minneapolis, MN 55401 USA RoadBike, Friction Zone, PowerSports, and Dealer News
magazines. Author of three books, Tracy co-authored the
© 2014 Quarto Publishing Group USA Inc. MSF’s Guide to Motorcycling Excellence, Second Edition.
Text and photography © 2014 Tracy Martin Published by Motorbooks, Tracy’s latest book, Motorcycle
Electrical Systems: Troubleshooting and Repair, is available
All photographs are from the author’s collection unless at booksellers everywhere. His first book, How to Diagnose
noted otherwise. and Repair Automotive Electrical Systems, is also available at
bookstores. In addition to writing, Tracy teaches the Total
All rights reserved. With the exception of quoting brief Control Advanced Riding Clinic with Lee Parks, author
passages for the purposes of review, no part of this of Total Control. Tracy has presented riding skills and
publication may be reproduced without prior written motorcycle suspension seminars across the United States and
permission from the Publisher. recently in England and the Russian Federation.
The information in this book is true and complete to
the best of our knowledge. All recommendations are
made without any guarantee on the part of the author
or Publisher, who also disclaims any liability incurred in
connection with the use of this data or specific details.
We recognize, further, that some words, model names,
and designations mentioned herein are the property of the
trademark holder. We use them for identification purposes
only. This is not an official publication.
Motorbooks titles are also available at discounts in bulk
quantity for industrial or sales-promotional use. For details
write to Special Sales Manager at Quarto Publishing Group
USA Inc., 400 First Avenue North, Suite 400, Minneapolis,
MN 55401 USA.
Digital edition: 978-1-62788-217-0
Softcover edition: 978-0-76034-536-8
To find out more about our books, visit us online at
www.motorbooks.com.
ISBN: 978-0-7603-4536-8
Editor: Darwin Holmstrom
Design Manager: Brad Springer
Layout Designer: Danielle Smith-Boldt
Cover Photography: Paul Markert
Printed in China
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Contents
Introduction................................................................4
Dedication.................................................................5
CHAPTER 1 Batteries................................................6
CHAPTER 2 Charging Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
CHAPTER 3 Starters................................................50
CHAPTER 4 Ignition Systems ........................................59
CHAPTER 5 Electronic Fuel Injection..................................90
CHAPTER 6 Wiring Diagrams .......................................131
CHAPTER 7 Electrical Projects ......................................151
Sources.................................................................195
Index ...................................................................205
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Introduction
If you are reading this you have bought my fifth addition to how to fix electrical things that don’t work,
book, or maybe you’re online and thinking about it. throughout the book there are many electrically related
This book on motorcycle electrical systems is different projects of all types and most are relatively easy to do. If
from my previous book on the same subject. It’s more you have ever wondered how to install a 12-volt relay (or
hands-on, with lots of photographs and graphics that I even why one would want to), or how to read a factory
hope will explain what to do when something electrical wiring diagram, these subjects are covered as well.
goes awry with your motorcycle. Often when faced I wanted to thank the people and companies that
with an electrical problem, many owner’s first step is helped me with many aspects of creating this book. The
to take their bike to a dealer and spend money. While motorcycle dealerships that kindly let me run amok in
this works most of the time, it’s not without pitfalls. their service departments, asking questions and looking
You have to get the motorcycle there, pick it up, and at factory manuals are all credited in the Sources section
of course, spend money for someone else to figure out at the end of the book. Likewise, the companies that
what’s wrong. Just like performing your own oil and donated products that appear as electrical projects are
filter changes, or other maintenance, repairing your also acknowledged in the Sources section. I had help
electrical system can provide owner satisfaction. Even with the photographs, and I thank Marc Connelly, Rick
if you ultimately have the dealer do the work, a little Haskings, Dennis Kreps, and Alan Lapp for taking a lot
knowledge about what they are working on can go a of the photos that ended up in the book. Thank you for
long way toward getting the most for your money. In all your hard work.
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Dedication
I wrote this book for my son, who at the young age only an ad slogan that I would occasionally read or
of 30 has had to make too many life-and-death see on TV, but after witnessing his struggle, it takes
decisions in his brave fight against cancer. His courage on a whole new meaning. I know that he will emerge
has been an inspiration to my wife and me as we from this nightmare intact and ready to move on with
watch him make it through each day of his treatment. his life.
Before his diagnosis, the term “cancer survivor” was With all my love, Dad.
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Chapter 1
Batteries
Three common types of
batteries: starting at the top
left, 12-volt conventional battery,
top right, 12-volt AGM battery (aka
maintenance free), and 6-volt battery (bottom). There
are several advantages to the AGM type of battery: no fill caps, and water
doesn’t ever have to be added during its service life. Courtesy Yuasa Battery, Inc.
Here are the parts that make up a Yuasa absorbed glass matt or AGM battery. The
polypropylene plastic case, cover, and filler caps form the “container” for the battery. The
cell group (lower left) consists of positive and negatives plates with glass mat separators in
between each plate. The three odd-shaped lead lugs are inter-cell connectors that attach the
cell groups to the positive and negative battery terminals. Courtesy Yuasa Battery, Inc.
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INTRODUCTION TO BATTERIES
Typically, most people don’t spend a lot of time
worrying about the battery in their motorcycle until the
engine won’t start; then it gets 100 percent attention.
Fortunately, a jump start can get the engine going,
but the bigger problem is whether it will start up again
once the engine is shut off. In addition to not starting
the engine, a weak or old battery can also lead to engine
performance issues with electronically fuel-injected
(EFI) bikes and cause problems with the charging
system. Understanding how batteries operate and how
to test and maintain them is simple. Basically batteries The size, or
perform three jobs: (1) to provide electrical power displacement in
cubic centimeters (cc),
to start the engine, (2) to supply additional current
of a motorcycle engine
determines the power required
by the starter motor to spin it fast
enough to start. This determines how
much capacity the battery needs to have
to provide the energy required to operate the starter motor.
when the charging system can’t keep up with electrical
demand, and (3) to act as a voltage stabilizer for the
motorcycle’s charging system.
A battery’s primary job is starting the engine, and BA
T
in this case, size does matter. Engine displacement is T
E
R
the determining factor for amperage requirements IE
S
for engine starting and related battery capacity.
The amperage required for starting an engine varies
depending upon the type and size of motorcycle
engine. For purposes of engine starting, batteries are
rated in two ways, amp/hour (Ah) and cold cranking
amps (CCA). Amp-hour rating is the battery’s ability
to deliver current for an extended period of time.
Cold cranking amperage is the battery’s ability to
produce current in low temperatures. In general, larger
batteries will have greater Ah and CCA ratings. There
are some high-performance batteries where this is not
true and physical size is not an indication of electrical
cranking power.
A battery’s second job is to supply current when
the charging system is overworked. This usually occurs
(though not always) when the engine is being operated
at lower speeds. If the motorcycle’s electrical system is
creating a high demand—headlights on, heated vest and
Batteries are gloves, stereo in use, and so on—and the engine’s speed
rated in amp hours (Ah) and
is too low for the charging system to supply enough
cold cranking amps (CCA). The larger the CCA and Ah
current for the power requirements of the motorcycle,
numbers the more energy it can produce. Larger motorcycle engines require
batteries with higher CCA and Ah ratings. Courtesy Yuasa Battery, Inc. the battery makes up the difference. This situation can
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only last for a short time, as the overworked charging because the charging output voltage could increase
system will not be able to keep the battery charged. to more than 20 volts—enough electrical pressure to
Eventually there won’t be enough electrical energy to “take out” many (if not all) solid-state components
run the engine’s ignition and fuel system and the engine such as ignition modules, computers, stereos, and
will stop running. so on.
The last function of a battery is to act as a
voltage stabilizer for the charging system. Charging
systems need something to push against to keep from
producing excessive voltage. A battery should never be
disconnected when the motorcycle’s engine is running
Pictured is an AGM battery case with the top off. The plates and
separators can from one of the six battery cells can be seen. Twelve-volt
S
E batteries have six cells that produce around 2 volts each; hence the six
RI
E cells produce 12 volts. Courtesy Yuasa Battery, Inc.
T
T
A
B
Pictured are a group of battery plates and separators. One negative plate,
These components make up a typical motorcycle-charging system. The a glass mat separator, and one positive plate make up the cells inside
stator (bottom) uses the rotating engine to produce alternating current, or an AGM, or maintenance-free battery. The white glass mats between the
AC. The rectifier (top) converts the AC current to DC (direct current), where plates absorb the electrolytic solution of sulfuric acid and distilled water.
it can be used to power everything electrical on the bike. Courtesy Yuasa Battery, Inc.
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