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Parts Location
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ELECTRICAL SYSTEM 16-3
ELECTRICAL SYSTEM
Junction Box Fuse Circuit
Water Temperature Warning
Turn Signal Light Bulb
Headlight Beam Vertical
Headlight Beam Horizontal
Commutator Cleaning and
Starter Clutch Sprocket
Starter Clutch Sprocket Removal. 16-25
Table of Contents
Parts Location.................................... 16-3
Exploded View................................... 16-4
Specifications................................... 16-10
Special Tools and Sealant................. 16-12
KLE500-B1 Wiring Diagram.............. 16-14
Precautions........................................ 16-16
Electrical Wiring................................. 16-18
Wiring Inspection......................... 16-18
Battery.............................................. 16-19
Battery Removal/Installation........ 16-19
Battery Activation......................... 16-19
Precautions.................................. 16-21
Interchange.................................. 16-22
Charging Condition Inspection.... 16-22
Refreshing Charge...................... 16-23
Charging System............................... 16-24
Alternator Rotor/Starter Clutch
Removal.................................... 16-24
Installation................................. 16-25
Alternator Rotor/Starter Clutch
Installation................................. 16-26
Alternator Stator Removal............ 16-26
Alternator Stator Installation......... 16-27
Alternator Inspection.................... 16-27
Regulator/Rectifier Removal........ 16-28
Regulator/Rectifier Output
Voltage Inspection..................... 16-28
Regulator/Rectifier Inspection...... 16-29
Ignition System.................................. 16-33
Crankshaft Sensor Removal........ 16-34
Crankshaft Sensor Installation..... 16-34
Crankshaft Sensor Inspection...... 16-34
Ignition Coil Removal/Installation. 16-35
Ignition Coil Inspection................. 16-35
Ignition Timing Inspection............ 16-36
Spark Plug Removal/Installation.. 16-36
Spark Plug Gap Inspection.......... 16-36
IC Igniter Removal....................... 16-37
IC Igniter Inspection..................... 16-37
Diodes Inspection........................ 16-41
Electric Starter System...................... 16-43
Starter Motor Removal................. 16-44
Starter Motor Installation.............. 16-44
Starter Motor Disassembly........... 16-44
Starter Motor Assembly............... 16-45
Brush Inspection.......................... 16-46
Brush Spring Inspection............... 16-46
Inspection.................................. 16-46
Armature Inspection..................... 16-47
Brush Plate Inspection................. 16-47
Starter Chain Guide Wear............ 16-47
Starter Relay Inspection............... 16-48
Lighting System................................. 16-49
Adjustment................................ 16-49
Adjustment................................ 16-49
Headlight Bulb Replacement....... 16-50
Headlight Unit/Housing Removal. 16-50
Headlight Unit/Housing
Installation................................. 16-51
City Light Bulb Replacement........ 16-51
Tail/Brake Light Bulb
Replacement............................. 16-51
Tail/Brake Light Lens
Removal/Installation.................. 16-52
Replacement............................. 16-52
Turn Signal Relay Inspection...... 16-52
Radiator Fan System........................ 16-54
Fan System Circuit Inspection.... 16-54
Fan Motor Inspection................... 16-54
Meter Unit......................................... 16-55
Meter Unit Removal..................... 16-55
Meter Unit Disassembly............... 16-55
Tachometer Inspection................. 16-56
Bulb Replacement........................ 16-56
System Inspection..................... 16-57
Switches and Sensors....................... 16-59
Brake Light Switch Inspection...... 16-59
Switch Inspection......................... 16-59
Radiator Fan Switch Inspection... 16-60
Water Temperature Switch
Inspection.................................. 16-61
Junction Box...................................... 16-62
Inspection.................................. 16-62
Starter Circuit/Headlight Relay
Inspection...................................... 16-62
Diode Circuit Inspection.............. 16-63
Fuses..................................................... 16-65
30 A Main Fuse Removal............... 16-65
Junction Box Fuse Removal........... 16-65
Junction Box Fuse Installation........ 16-65
Fuse Inspection........................... 16-65
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Starter Lockout Switch
Radiator Fan
Radiator Fan Switch
#1 Ignition Coil
Starter Motor
Sealed Battery
IC Igniter
Junction Box
alternator
Crankshaft Sensor
Oil Pressure Switch
Neutral Switch
Sidestand Switch
Horn
Spark Plugs
Water Temperature Switch
Regulator/Rectifier
Main Fuse 30 A
Starter Relay
Turn Signal Relay
Rear Brake Light Switch
Front Brake Light Switch
Ignition Switch
#2 Ignition Coil
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