2 - | Battery charging system

Checking the battery charging system
To check the current flow in the charging circuit, use the “DDS” tester, which is equipped with an inductive clamp-type ammeter.
Follow the instructions given in the paragraph “Testing the battery charging system” (Sect. D 5).
A negative value means that charging system is not powering the loads and a significant amount of current must be supplied by the battery, which is discharging at the time of the measurement.
Alternatively, you can use a multimeter (Sect. P 9, Diagnostic instruments): connect the multimeter probes to the battery terminals, select the DC scale on the instrument and check for the presence of 14.5 V ±0.5 at an engine speed of 3000 rpm.
Important
If polarity is reversed when clamping the ammeter onto the cable, the sign of the readings will also be reversed, giving rise to incorrect diagnosis.
Recharging the battery
Examine the label on the battery showing the check intervals in order to determine when to test the voltage.
Charge the battery if the open circuit voltage is lower than 12.8 V. Leaving the battery discharged for more than one month could damage it. Check the battery charge with a voltmeter.
Always check the condition of the battery before recharging and 1 to 2 hours afterwards.
Important
Pay careful attention to recharging times. Stop charging immediately if the battery becomes too hot to the touch. Leave to cool before resuming charging.
Use only constant-voltage battery chargers.
Check that battery terminals are properly connected to the battery charger.
For recharging, follow the instructions on the battery; for further details consult the table below.

Type of charging | Volt. | Ampere (A) | Time (Hours)
Normal | 12 | 1.2 | 5-10
Fast | 12 | 5.0 | 1

Use fast charging in emergencies only.
Storing the battery
If the battery voltage is less than or equal to 11.5 V, it must be recharged.
Connect the battery charger to the battery.
Use a voltage of 16-17 V.
If the ammeter shows no change, increase the voltage to the maximum of 25 V.
Charge for 5 minutes.
If the ammeter shows a change, return the voltage to 16-17 V; otherwise replace the battery.
Topping up the electrolyte
Remove the battery from the motorcycle.
Warning
Read carefully the relevant safety rules before working on the battery (Sect. A 3, General safety rules).
The electrolyte in the battery is toxic and can cause burns if it comes into contact with the skin because it contains sulphuric acid.
Wear protective clothing, a face-mask and goggles when adding electrolyte.
If the liquid comes into contact with the skin, wash thoroughly with cold water. If it comes into contact with the eyes, wash thoroughly with water for 15 minutes and consult an ophthalmologist. In the event of accidental ingestion, drink large quantities of water or milk, and continue with milk of magnesia, beaten egg or vegetable oil. Do not allow sparks, flames, cigarettes or any other heat source to come near the battery, as it produces explosive gases.
When recharging or using the battery indoors, make sure that the room is adequately ventilated. Do not inhale the gases produced during recharging.
KEEP OUT OF REACH OF CHILDREN.
Place the battery on a flat surface.
Remove the protective film (1).
Warning
Make certain that the electrolyte is of the specific type for your battery.
Remove the container with the electrolyte from the vinyl bag.
Remove the cap strip (3) from the container (2).
Important
Keep the cap strip (3) to hand because it will be used later as caps for the battery cells.
Warning
Do not peel or perforate the sealed areas.
Place the electrolyte container (2) upside down. Align the six sealed elements with the six filler holes on the battery.
Push the container (2) downwards with sufficient force to break the seals and allow the liquid to flow out.
Notes
Do not tilt the electrolyte container as this could interrupt the flow temporarily or even permanently.
Make certain that air bubbles emerge from all six filler holes. Leave the container in this position for at least twenty minutes. If no bubbles emerge from one of the holes, tap gently on the bottom of the respective container.
Important
Never move the container away from the battery. Do not cut or puncture the liquid container.
Make sure that all the electrolyte has flowed out. Carefully extract the container (2) from the battery.
Place the sealing cap strip (3) previously removed from the electrolyte container (2) on the battery, taking care not to force it into the filler holes.
For 3-12 Ah batteries, leave to stand for at least 30 mins.
For batteries of over 12 Ah, leave to stand for at least 1 hour.
Notes
If using an automatic charge reducing battery charger, make certain that the charger current (amps) is greater than or equal to the standard (STD) recharging system indicated on the battery.
Press down firmly with both hands until the caps are firmly in place (do not use a hammer).
Battery
Safety rules
Warning
Read carefully the relevant safety rules before working on the battery (Sect. A 3, General safety rules). When under charge, batteries produce explosive gases. Keep batteries away from heat sources, sparks or open flames.
Instructions for use
The battery is a sealed, maintenance-free type and therefore requires no servicing installation.
Notes
Always keep the battery clean. Apply grease around the battery terminal clamps to prevent corrosion.
Warning
Never remove the retainer bar (1) on the top of the cover or add more liquid to the battery. If the casing, the cover or the terminals are broken, or if the sealing cap strip has been tampered with, the battery must be renewed.
Important
If the motorcycle is left unused for more than 30 days, remove the battery and store it in a safe, cool place.
Always charge the battery before the first use and after long storage periods - such as before selling the vehicle.
Removal of the battery
Notes
References (16) and (19) are the same as those indicated in the plates in the chapter “Routing of wiring on frame” in this section.
Remove the fuel tank (Sect. L 2, Removal of the fuel tank).
Release the elastic retaining strap (2), then withdraw the battery.
Remove the protective caps from the terminals, unscrew the screws of the terminals (16) and (19), always starting with the negative terminal.
Refitting the battery
Install the battery in the battery support and secure it with the elastic retaining strap (2).
Warning
Connect the positive lead (19) to the positive terminal and the negative lead (16) to the negative terminal, as shown in the photo.
Insert the screws in the terminals (16) and (19) always starting with the positive terminal (red lead).
Warning
Position the leads (16) and (19) as shown in the photo.
Tighten the terminal screws to the specified torque (Sect. C 3, Frame torque settings) and apply grease to the terminals to prevent corrosion.
Fit the protective caps to the battery terminals.
Battery support
Remove the battery as described in this section in the paragraph “Battery”.
Remove the vertical cylinder coil as described in Sect. M 3, Coil.
Unscrew the screws (7) and screw (5) and remove the battery support from the airbox.
Refit the components reversing the order in which they were removed; tighten the screws to the specified torque (Sect. C 3, Frame torque settings).
Alternator
The motorcycle is equipped with a 12 V, 520 W alternator, consisting of a stator (A) located in the left-hand side crankcase cover and a rotor (B) fixed to the crankshaft.
Warning
To check the charging system for faults, use the DDS tester and follow the instructions given under the heading “Testing the battery charging system” (Sect. D 5).
The absolute value of voltage measured across the terminals of two of the three yellow cables (the measured value will be the same whichever combination of cable is used) must be within the range indicated in the table below.
(Ambient temperature: 20 °C)
Important
Before testing, disconnect the alternator wiring from the electrical system when the ignition key is set to OFF.

Engine rpm | 2000 | 6000
effective V | 27±10 | 78±10

Values significantly lower than those indicated above can be due to:
partially demagnetised rotor;
short-circuited windings.
In the above cases the whole alternator assembly (rotor and stator) should be renewed.
If checks have a favourable outcome, reconnect the alternator to the regulator with ignition key on OFF. Make sure that no cables are damaged or disconnected.
Removal of the alternator
Disconnect the alternator wires from the electrical system (refer to plate in chapter “Routing of wiring on frame”, Sect. P 1).
Remove the alternator-side crankcase cover, the stator (A) and rotor (B) (Sect. N 8, Removal of the alternator-side crankcase cover).
Refitting the alternator
Fit the rotor (B), the stator (A) and the alternator-side crankcase cover.
Connect the alternator wiring from the electrical system (refer to plate in chapter “Routing of wiring on frame”, Sect. P 1).
Rectifier-regulator
The regulator (1) is fixed to the RH air scoop (2).
The rectifier/regulator consists of an aluminium casing containing the diodes that rectify the current produced by the alternator. It also contains an electronic device that regulates the current supplied by the alternator in accordance with battery voltage.
If the battery is drained, the current has the value necessary to restore optimum operating conditions of the battery.
In contrast, if the battery is fully charged, the current value will be lower.
Notes
Check the charging current using the DDS tester, following the instructions given in the paragraph “Testing the battery charging system” (Sect. D 5).
Removal of the regulator
Unscrew the screws (1) securing the LH air scoop (2) to the frame.
Release the clutch hose (A) from the LH air scoop (2).
Unscrew the screw (3) amd remove the LH air scoop (2) from the RH air scoop (4).
Undo the screws (5) and remove the RH air scoop (4) from the frame.
Disconnect the alternator/regulator connector (B) from the main wiring harness (Sect. P 1, Routing of wiring on frame).
Remove the regulator (7) from the RH air scoop (4) by unscrewing the two screws (6).
Important
Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator.
Refitting the regulator
Check that the two threaded clips (8) are installed on the RH air scoop (4) and positioning as shown in the figure.
Fix the regulator (7) to the RH air scoop (4) with the two screws (6).
Tighten the screws (6) to the specified torque (Sect. C 3, Frame torque settings).
Connect the alternator/regulator connector (B) to the main wiring harness (Sect. P 1, Routing of wiring on frame).
Refit the RH air scoop (4) and tighten the screws (5) to the specified torque (Sect. C 3, Frame torque settings).
Fix the clutch hose (A) to the LH air scoop (2).
Refit the LH air scoop (2) to the RH air scoop (4) with the screws (3).
Refit the LH air scoop (2) to the frame and tighten the screws (1) to the specified torque (Sect. C 3, Frame torque settings).
Notes
To position the regulator wiring correctly, designated (14), follow the indications in plate E in the chapter “Routing of wiring on frame”, Sect. P 1.
Regulator fuse
The 30 A fuse located on the airbox protects the electronic regulator. To gain access to the fuse, remove the fuel tank (Sect. L 2, Removal of the fuel tank) and disconnect the regulator (A).
A blown fuse can be identified by breakage of the inner filament (B).
Important
Switch the ignition key to OFF before replacing a fuse to avoid possible short circuits.
Warning
Never use a fuse with a rating other than the specified value. Failure to observe this rule may damage the electric system or even cause fire.
P