Honda CBR125RW - Service manual > Battery/Charging System
SYSTEM LOCATION
- REGULATOR/RECTIFIER
- ALTERNATOR
- BATTERY
- MAIN FUSE (30A)
SYSTEM DIAGRAM
SERVICE INFORMATION
GENERAL
! WARNING
- The battery gives off explosive gases; keep sparks, flames away. Provide adequate ventilation when charging.
- The battery contains sulfuric acid (electrolyte). Contact with
skin or eyes may cause severe burns. Wear protective clothing and a face
shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
- Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immediately.
- Always turn OFF the ignition switch before disconnecting any electrical component.
- Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.
- For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every 2 weeks.
- For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal.
- The maintenance free battery must be replaced when it reaches the end of its service life.
- The battery can be damaged if overcharged or undercharged, or if left to discharge for a long period. These same conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2 - 3 years.
- Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly.
- Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and tail light ON for long periods of time without riding the motorcycle.
- The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent sulfation from occurring.
- When checking the charging system, always follow the steps in the troubleshooting flow chart.
BATTERY CHARGING
- Turn power ON/OFF at the charger, not at the battery terminal.
- For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery.
- Quick charging should only be done in an emergency; slow charging is preferred.
BATTERY TESTING
Refer to the instruction of the Operation Manual for the recommended battery tester for details about battery testing. The recommended battery tester puts a "load" on the battery so the actual battery condition can be measured.
Recommended battery tester BM-210 or BATTERY MATE or equivalent
SPECIFICATIONS
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
1. BATTERY TEST
Remove the battery.
Check the battery condition using a recommended battery tester.
RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent
Is the battery in good condition?
NO - Faulty battery
YES - GO TO STEP 2.
2. CURRENT LEAKAGE TEST
Install the battery.
Check the battery current leakage test (Leak test).
Is the current leakage below 0.1 mA?
YES - GO TO STEP 4.
NO - GO TO STEP 3.
3. CURRENT LEAKAGE TEST WITHOUT REGULATOR/RECTIFIER CONNECTOR
Disconnect the regulator/rectifier 6P (Black) connector and recheck the battery current leakage.
Is the current leakage below 0.1 mA?
YES - Faulty regulator/rectifier
NO -
- Shorted wire harness
- Faulty ignition switch
4. CHARGING VOLTAGE INSPECTION
Measure and record the battery voltage using a digital multimeter.
Start the engine.
Measure the charging voltage.
Compare the measurements to the results of the following calculation.
STANDARD: Measured BV < Measured CV < 15.5 V
- BV = Battery Voltage
- CV = Charging Voltage
Is the measured charging voltage within the standard voltage?
YES - Faulty battery
NO - GO TO STEP 5.
5. ALTERNATOR CHARGING COIL INSPECTION
Check the alternator charging coil.
Is the alternator charging coil resistance within 0.2 - 0.6 Ω (20ºC/68ºF)?
YES - Faulty charging coil
NO - GO TO STEP 6.
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
Check the voltage and resistance at the regulator/rectifier 6P (Black) connector.
Are the measurements correct?
YES - Faulty regulator/rectifier
NO -
- Open circuit in related wire
- Loose or poor contacts of related terminal
- Shorted wire harness
BATTERY
REMOVAL/INSTALLATION
Remove the single seat.
Turn the ignition switch OFF.
Remove the trim clip and open the battery case cover.
Disconnect the negative (-) cable first and then the positive (+) cable.
Remove the battery.
Connect the positive cable first and then the negative cable.
Install the battery in the reverse order of removal.
VOLTAGE INSPECTION
Measure the battery voltage using a commercially available digital multimeter.
VOLTAGE (20ºC/68ºF):
Fully charged: 13.0 - 13.2 V
Under charged: Below 12.4 V
If the battery voltage is below 12.4 V, charge the battery.
BATTERY TESTING
Refer to the instructions that are appropriate to the battery testing equipment available to you.
TOOL: Battery tester BM-210 or BATTERY MATE or equivalent
CHARGING SYSTEM INSPECTION
CURRENT LEAKAGE INSPECTION
Remove the single seat.
Open the battery case cover.
With the ignition switch turned OFF, disconnect the negative (-) cable.
Connect the ammeter (+) probe to the wire harness negative (-) cable and ammeter (-) probe to the battery negative (-) terminal.
With the ignition switch turned OFF, check for current leakage.
NOTE:
- When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow the fuse in the tester.
- While measuring current, do not turn the ignition switch ON. A sudden surge of current may blow the fuse in the tester.
SPECIFIED CURRENT LEAKAGE: 0.1 mA max.
If current leakage exceeds the specified value, a shorted circuit is likely.
Locate the short by disconnecting connections one by one and measuring the current.
CHARGING VOLTAGE INSPECTION
Remove the single seat.
Open the battery case cover.
Be sure the battery is in good condition before performing this test.
Warm up the engine to normal operating temperature.
Connect the multimeter between the battery positive (+) and negative (-) terminal.
NOTE:
- To prevent a short, make absolutely certain which are the positive (+) and negative (-) terminal or cable.
- Do not disconnect the battery or any cable in the charging system without first turning the ignition switch OFF. Failure to follow this precaution can damage the tester or electrical components.
With the headlight high beam, measure the voltage on the multimeter when the engine runs at 5,000 min-1 (rpm).
STANDARD: Measured BV < Measured CV < 15.5 V
- BV = Battery Voltage
- CV = Charging Voltage
ALTERNATOR CHARGING COIL
INSPECTION
It is not necessary to remove the stator coil to perform this test.
Disconnect the alternator/CKP sensor 6P (Natural) connector.
Measure the resistance between the Yellow wire terminals of the alternator side connector.
STANDARD: 0.2 - 0.6 Ω (20ºC/68ºF)
Replace the alternator stator if the resistance is out of specification, or if any wire has continuity to ground.
REGULATOR/RECTIFIER
SYSTEM INSPECTION
It is not necessary to remove the stator coil to perform this test.
Turn the ignition switch OFF.
Disconnect the regulator/rectifier 6P (Black) connector, and check it for loose contacts or corroded terminals.
If the charging voltage reading is out of the specification, check the following at the wire harness side connector:
If all components of the charging system are normal and there are no loose connections at the regulator/ rectifier connector, replace the regulator/rectifier unit.
REMOVAL/INSTALLATION
Remove the left middle cowl.
Disconnect the regulator/rectifier 6P (Black) connector.
Remove the bolts and regulator/rectifier from the frame.
Install the regulator/rectifier in the reverse order of removal.
See also:
Honda CBR125RW - Service manual > Ignition System
SYSTEM LOCATION CLUTCH SWITCH IGNITION SWITCH IGNITION COIL ECM INJECTOR MAIN FUSE (30 A) BATTERY SUB FUSE SIDESTAND SWITCH NEUTRAL SWITCH CKP SENSOR SPARK PLUG