7 CHARGING SYSTEM GENERAL 5682 Voltage regulator The charging system consists of the alternator and regulator. See page 7-25 for charging system circuits. Alternator The alternator consists of two main components: the rotor which is mounted on the engine sprocket shaft, and the stator, which is bolted to the engine crankcase. Voltage Regulator See Figure 7-18. The voltage regulator is a series regulator with shunt control. The circuit combines the functions of rectifying and regulating. Figure 7-18.
Charging System Troubleshooting NOTE Whenever a charging system component fails a test and is replaced, the system must be re-tested to be sure problem has been corrected. SYMPTOM: BATTERY BECOMES DISCHARGED Test battery. Charge or replace as required. See BATTERY in Section 1. Pass Correct as required. Inspect regulator. See REGULATOR INSPECTION. Fail Pass Replace regulator. Test regulator. See REGULATOR BLEED TEST. Fail Pass Isolate damaged component or wiring.
b0240x7x BK MASTER 30A CIRCUIT BREAKER BK VOLTAGE REGULATOR BK BK BK 1 2 P17 BK BK BATTERY LT.BE COLOR CODE: STATOR LIGHT BLUE BE BLUE GY GRAY TN TAN BK BLACK O ORANGE V VIOLET BN BROWN PK PINK W WHITE GN GREEN R RED Y YELLOW DIODE XX CABLE COLOR XX STRIPE COLOR NO CONNECTION CONNECTION PIN CONNECTOR SOCKET CONNECTOR Figure 7-19.
TESTING 3 milliamperes maximum flt0808 Voltage Regulator Bleed Test Be sure regulator is connected to battery. Unplug regulator connector to engine crankcase. Use a trouble light and touch one probe to a known good ground and the other to the regulator pins, one at a time. If light glows, replace regulator. Amp 12 VDC battery Milliampere Draw Test Ignition OFF NOTE Be sure accessories are not wired so they stay on at all times.
Current and Voltage Output Test 1. d0005x8x Load tester See Figure 7-22. Connect load tester. a. Connect negative and positive leads to battery terminals. b. Place load tester induction pickup over positive regulator cable. 2. Run the engine at 2000 RPM. Increase the load as required to obtain a constant 13.0 VDC. 3. The current output should be 19-23 amps. Make note of measurement. To circuit breaker (DC output) Voltage Output Test See Figure 7-22.
AC Output Check 1. See Figure 7-25. Test AC output. a. Disconnect voltage regulator wiring at connector [P17]. b. Connect an AC voltmeter across both stator sockets. c. Run the engine at 2000 RPM. The AC output should be 38-52 volts AC. 2. 3. 5685a Compare test results to specifications. a. If the output is below specifications, charging problem could be a faulty rotor or stator. b. If output is good, charging problem might be faulty regulator/rectifier. Replace as required.
ALTERNATOR REMOVAL/DISASSEMBLY 1WARNING 3558 Rotor Blocking To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion producing personal injury. 1CAUTION Hold battery cable when loosening battery terminal hardware. Failure to hold cable may cause battery damage. 1.
CLEANING, INSPECTION AND REPAIR 3560 Pipe section Rotor 1CAUTION Do not strike or drop alternator rotor or damage to magnet adhesive may occur. Magnet adhesive damage can result in rotor failure. 1. Clean rotor with a petroleum-base solvent. Remove all foreign material from rotor magnets. Replace rotor if rotor magnets are cracked or loose. 2. Clean stator by wiping with a clean cloth. 3. Examine stator leads for cracked or damaged insulation.
VOLTAGE REGULATOR GENERAL b0227x7x The voltage regulator is on the right side next to the battery. The voltage regulator is not repairable. Replace the unit if it fails. BK R MASTER CIRCUIT BREAKER 30A BK REMOVAL VOLTAGE REGULATOR 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative cable first.
BATTERY GENERAL ● ● b0228x7x 1WARNING Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes or clothing. 1 3 Batteries produce explosive hydrogen gas at all times, especially when being charged. Keep cigarettes, open flame and sparks away from the battery at all times. Ventilate area when charging battery. Always protect hands and protect eyes with shield or goggles when working near a battery or acid.
HEADLAMP REMOVAL b0231x7x 13 Headlamp and Bulbs 1. See Figure 7-32. Loosen screw (10) at bottom of headlamp. 2. Pry headlamp (9) from headlamp housing (13). 3. See Figure 7-33. Press retaining clip (4) and remove position lamp bulb (3) from headlamp. Twist bulb to remove from harness. 3 4 12 5 11 7 1 1WARNING 8 2 6 The bulb contains Halogen gas under pressure. Handle bulb careful and wear eye protech to avoid possible personal injury. 1CAUTION Never touch the bulb with your fingers.
INSTALLATION Headlamp Brackets and Housing 1. a. Install front forks through triple clamps and brackets. See FRONT FORK, INSTALLATION in Section 2. b. See Figure 7-32. Install four bolts (5) and locknuts (3). Wire guide and two washers go on lower bolt on right headlamp bracket. Place wires into wire guide. d. 3. RIGHT FRONT TURN SIGNAL R/BK BN BE BK Install headlamp brackets. c. 2. b0229x7x Place windscreen brackets on the inside of the headlamp brackets. Install front turn signals.
TAIL LAMP REMOVAL/DISASSEMBLY b0234x7x 3 Tail Lamp 1. 1 See Figure 7-35. If necessary, remove tail lamp bulb (3). a. Remove two screws (1) to detach tail lamp lens. b. Turn bulb counterclockwise and remove. 2. Remove two locknuts (7) (metric) and washers (6). 3. Disconnect the three terminals and remove tail lamp. 4 2 5 6 Tail Lamp Bracket 1. Remove seat and tail section. See TAIL SECTION, REMOVAL in Section 2. 2. See Figure 7-36.
Tail Lamp 1. b0230x7x See Figure 7-37. Install the three tail lamp wires. BN BK NOTE Early 1996 models may have a blue wire in slot 7 of connector [P11]. This wire does not have a terminating connection. Cable strap this wire to the other harness wires. 2. TAIL LAMP AND REAR TURN SIGNALS BK Turn bulb clockwise to install. b. Install tail lamp lens with two screws (1).
TURN SIGNALS REMOVAL b0232x7x Front 1. Remove headlamp mounting screws (metric) and washers. 2. See Figure 7-38. Disconnect bullet connectors (5). 3. Remove screws (1) (metric) and locknuts (6) (metric). 4. Remove turn signals and standoffs (4). 8 Rear 1. See Figure 7-38. Cut cable straps to access bullet connectors under tail section. Disconnect bullet connectors. 2. Remove screws (9) (metric) and nuts (6) (metric). 3. Remove turn signals from tail lamp bracket (7).
TURN SIGNAL FLASHER REMOVAL 5682 NOTE The turn signal flasher is not repairable. Replace the unit if it fails. 1. Remove seat and tail section. See TAIL SECTION, REMOVAL in Section 2. 2. See Figure 7-39. Remove screw from clamp. 3. Remove turn signal flasher and detach both wires. Flasher INSTALLATION 1. See Figure 7-39. Connect both wires to flasher. 2. Place flasher inside clamp so prongs on flasher face inside and down. 3. Install on flasher and clamp on frame with screw.
HANDLEBAR SWITCHES REMOVAL b0235x7x NOTE The individual handlebar switches are not repairable. Replace the switch assembly upon switch failure. Right Side 1. See Steps 1-5 of THROTTLE CONTROL, REMOVAL/ DISASSEMBLY in Section 2. 2. Remove seat and fuel tank. See FUEL TANK, REMOVAL in Section 4. 3. See Figure 7-40. Cut as many cable straps as necessary to access right handlebar switch connector [P1] along right side frame tube. Detach connector [P1] from wiring harness.
Left Side 1. Attach switch housing to handlebar with three screws (metric). Tighten screws to 25-33 in-lbs (2.8-3.7 Nm). 2. See Figure 7-41. Route switch housing wiring harness between front forks and along right side frame tube. Attach connector [P6] to wiring harness. Fasten wiring harness to frame with new cable straps. 3. Install fuel tank and seat. See FUEL TANK, INSTALLATION in Section 4. LEFT HANDLEBAR SWITCH CONNECTOR P6 LOW BEAM W HIGH BEAM BK LIGHT POWER BN RIGHT TURN LT.
HORN REMOVAL 1. Remove ignition coil to detach horn bracket from frame. See IGNITION COIL, REMOVAL on page 7-17. 2. See Figure 7-42. Remove power wire (6) from spade connection. 3. Detach ground wire (4) from horn by removing locknut (1) (metric) and washer (3). b0081a7x 6 1 INSTALLATION 1. See Figure 7-42. Install horn on bracket with ground wire (4), washer (3) and locknut (1) (metric). 2. Attach power wire (6). 3. Install horn and ignition coil. See IGNITION COIL, INSTALLATION on page 7-17.
NEUTRAL INDICATOR SWITCH GENERAL xlh0733 See Figure 7-43. The neutral indicator switch (1) is threaded into the transmission portion of the right crankcase half (2); it is immediately forward of the main drive gear shaft (3). The sprocket cover must be removed to test the switch. If switch requires replacement, secondary drive belt and transmission sprocket must also be removed; there is not enough clearance to allow the removal of the switch without first removing the transmission sprocket.
FUSES AND CIRCUIT BREAKERS GENERAL 5682 Fuse block The S1 Lightning features two components which protect the electrical system. 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before servicing motorcycle. Always disconnect the negative cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion producing personal injury. Spare fuse Fuses See Figure 7-44.
ELECTRICAL CONNECTORS GENERAL The following table provides a brief description of the connectors found on the S1 Lightning. Approximate locations of each connector are shown in Figure 7-46. Connector numbers are listed in [brackets] in this manual. Table 7-5.
b0222x7x 28 NOTE Only three wires are used to connect the tail lamp (28). See TAIL LAMP, ASSEMBLY/INSTALLATION on page 7-35. 27 Approximate diode location. See DIODES on page 7-21. 26 29 22 25 24 20 19 21 23 18 17 16 15 14 30 13 31 12 11 1 2 3 10 6 4 8 5 7 1. 2. 3. 4. 5. 6. Voltage regulator/stator [P17] Starter relay [P13] Timer and pickup [P16] Battery positive cable Starter Left handlebar switch housing [P6] 7. Oil pressure switch 8. Neutral indicator switch 9.
DEUTSCH ELECTRICAL CONNECTORS GENERAL b0070x3x The Deutsch Connector features a superior seal to protect electrical contacts from dirt and moisture in harsh environments. The connector also provides better pin retention than previous connectors. REMOVING/INSTALLING SOCKETS 1. 2. 3. 4. ● ● See Figure 7-47. Remove the secondary locking wedge (6).
CRIMPING INSTRUCTIONS 1. 2. 3. 4. 5. x0014x7x See Figure 7-49. Squeeze the handles to cycle the DEUTSCH TERMINAL CRIMP TOOL (Part No. HD39965) to the fully open position. Raise locking bar by pushing up on bottom flange. With the crimp tails facing upward and the rounded side of the contact barrel resting on the concave split level area of the crimp tool, insert contact (socket/pin) through middle hole of locking bar. Release locking bar to lock position of contact.
AMP MULTILOCK ELECTRICAL CONNECTORS REMOVING SOCKET/PIN TERMINALS 5. 1. If necessary, cut any surrounding cable straps to gain access to the connector. 2. See Figure 7-50. Depress the button on the socket terminal side of the connector (plug) and pull apart the pin and socket halves. 3. Bend back the latch slightly and free one side of secondary lock, then repeat the step to release the other side. Rotate the secondary lock outward on hinge to access terminals in chambers of connector housing. 4.
INSTALLING SOCKET/PIN TERMINALS NOTE For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. terminal (on the side opposite the crimp tails) must face downward. On the socket side, tangs are at the top of each chamber, so the socket terminal slot (on the same side as the crimp tails) must face upward.
CRIMPING INSTRUCTIONS 1. See Figure 7-53. Squeeze the handles to cycle the AMP TERMINAL CRIMP TOOL (Part No. HD-41609) to the fully open position. 2. Raise locking bar by pushing up on bottom flange. With the crimp tails facing upward, insert contact (socket/pin) through locking bar, so that the closed side of the contact rests on the nest (concave split level area) of the crimp tool). Use the front nest for 20 gauge wire, the middle for 16 gauge and the rear for 18 gauge. 3.
b0245x7x BN BK RIGHT TURN FLASHER VACUUM SWITCH OIL PRESSURE TIMER AND PICKUP BK BK O/W HIGH BEAM W BK LEFT TURN V BK P7 2 1 BK R/W Y/BK HORN V/BN TN O BK V/W NEUTRAL BK V/W GN/W PK R/W BK/W W/BK SPEEDOMETER ELECTRONIC IGNITION GN/Y O O/W BK/W R/Y GN/Y TN GN/W BE W/R GN/BK Y/O GY W/BK W/BK BK/R 1 2 3 4 P2 ACC POWER O/W TO STOPLIGHT R/Y O/W W/GN BK O PK TACHOMETER O/W R/Y 1 2 P10 R/Y BK V/W GN/W PK R/W BK/W W/BK P1 IGN POWER IGN MODULE FROM (2) TO STARTER 8 7 6 5 4 3
