TGB TARGET 400 425 ATV Full Service & Repair Manual

Home page Contents 17. ELECTRICAL SYSTEM Mechanism Diagram ·························· 17-1 Maintenance Data ······························· 17-2 Technical Specification······················17-2 Trouble Diagnosis ······························ 17-3 Battery ················································· 17-4 Charging System ································ 17-5 Ignition System··································· 17-8 Starting System ·································· 17-10 Meters ················································· 17-12 Light / Bulb········································· 17-13 Switch / Horn······································ 17-16 Fuel Unit ············································· 17-19 Cooling Fan Thermo Switch ············· 17-20 Thermo unit········································ 17-21 Water Temperature Indicator Light ·· 17-21 Mechanism Diagram Battery Fuse box Front brake switch Starter relay Hazard control unit Winker relay Main switch Shift gear control unity Rear brake switch C.D.I. Unitx Thermo unit Headlight relay Start & light & winker & horn & brake switch Horn Rectifier Ignition coil AC.Generator Spark plug Change switch 17-1 17 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Maintenance Data Operational precaution ● When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) ● The model of the spark plug and the tightening torque. ● The ignition timing. ● Adjustment of headlight. ● Removal and installation of AC generator. ● The maintenance free battery requires no inspection of electrolyte level and refilling of distilled water. ● To recharge the battery, remove the battery from rack without removing ventilation caps. ● Unless in emergency, never rapid charge the battery. ● The voltage must be checked with the voltmeter while charging the battery. ● As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect, check C.D.I and AC generator. Verify with an ignition timing light after replacement if necessary. Technical Specification Charging system Description Specification Battery Capacity 12V18Ah Charging rate 1.4A / 5 ~ 10 hours (standard) 14A / 0.5 hour (fast charging) Leak current < 1mA Charging current 1.2 A / 1500rpm Control voltage in charging 14.5 + 0.5 V / 1500rpm Ignition system Description Specification Spark plug Ignition coil and Model NGK CR7E (Recommended) Gap 0.8mm Primary winding 2.9 ± 10%Ω Without cap: 15. ± 10KΩ resistance Secondary winding Ignition timing “F” mark With cap:20 ± 10KΩ 15° TDC / 1700rpm 46°TDC / 4200rpm 17-2 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Trouble Diagnosis No voltage ● Battery discharged ● The cable disconnected ● The fuse is blown ● Improper operation of the main switch Low voltage ● The battery is not fully charged ● Poor contact ● Poor charging system ● Poor voltage regulator No spark produced by spark plug ● The spark plug is out of work ● The cable is poorly connected, open or short-circuited - Between AC.G. and C.D.I. ● Poor connection between C.D.I. and ignition coil - Poor connection between C.D.I. and the main switch ● Poor main switch ● Poor C.D.I. ● AC.G. is out of work Starter motor does not work ● The fuse is blown ● The battery is not fully charge ● Poor main switch ● Poor starter switch ● The front and rear brake switches do not operate correctly ● Starter relay is out of work ● The ignition coil is poorly connected, open or short-circuited ● The starter motor is out of work Intermittent power supply ● The connector of the charging system becomes loose ● Poor connection of the battery cable ● Poor connection or short-circuit of the discharging system ● Poor connection or short-circuit of the power generation system Charging system does not operate properly ● Burnt fuse ● Poor contact, open or short circuit ● Poor regulator ● Poor ACG Engine does not crank smoothly ● Primary winding circuit - Poor ignition coil - Poor connection of cable and connectors - Poor main switch ● Secondary winding circuit - Poor ignition coil - Poor spark plug - Poor ignition coil cable - Current leakage in the spark plug ● Incorrect ignition timing - Poor AC.G. - Improper installation of the pulse sensor - Poor C.D.I. Weak starter motor ● Poor charging system ● The battery is not fully charged ● Poor connection in the windings ● The motor gear is jammed by foreign material Starter motor is working, but engine does not crank ● Poor starter motor pinion ● The starter motor run in reverse direction ● Poor battery 17-3 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Battery Removal Remove the seat, and then you can see the battery. Disconnect the negative cable terminal first, then the positive cable terminal. Remove the battery clamp, and then remove battery. Clamp Voltage Check Use the digital voltmeter to check the voltage of the battery. Voltage: Fully charged: 13.0~13.2 V at 20℃ Undercharged: Below 12.3 V at 20℃ Charging Connect the positive terminal (+) of the charger to the battery positive terminal (+). Connect the negative terminal (-) of the charger to the battery negative terminal (-). Standard Maximum Charging current 1.8A 18.0A Charging time 5H 0.5H Warning ● Keep flames away while recharging. ● Charging is completely controlled by the ON/OFF switch on the charger, not by battery cables. Caution ● Never rapid charge the battery unless in emergency. ● Verify the battery is recharged with current and duration prescribed above. ● Large current and fast time to charge will render damage to the battery. When installing the battery, coat the cable terminal with grease. 17-4 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Charging System Charging circuit Main switch Black Blue B/R Yellow Yellow Yellow Battery Regulator rectifier AC. Generator Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Connect an ammeter between the negative cable terminal and the battery negative terminal. Caution ● In the current leakage test, set the current range at the largest scale, then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse. ● Do not turn the main switch to ON position during test. If the leaked current exceeds the specified value, it may indicate a short circuit. Allowable current leakage: Less than 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit. Battery negative terminal 17-5 Fuse 20A PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Charging Voltage Voltmeter Ammeter Connect a tachometer. Turn on the headlight to high beam and start the engine. Accelerate the engine to the specified revolution per minute and measure the charging voltage. Specified Charging Current: 1.2 A / 6000 rpm Control Charging Voltage: 14.5 + 0.5 V / 2000 rpm Fuse connector Caution To replace the old battery, use a new battery with the same current and voltage. Caution ● Before conducting the inspection, be sure that the battery is fully charged. If undercharged, the current changes dramatically. ● Use a fully charged battery having a voltage larger than 13.0 V ● While starting the engine, the starter motor draws large amount of current from the battery. After the engine is warmed up, replace original battery with a fully charged battery. Connect a digital voltmeter to the battery terminals. Connect an ammeter between both ends of the main fuse. Caution When the probe is reversibly connected, use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero, ammeter at one direction only. Caution ● Does not use short-circuit cable. ● It is possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal, however, while the starter motor is activated, the surge current the motor draws from the battery may damage the ammeter. Use the kick starter to start the engine. ● The main switch shall be turned to OFF position during the process of inspection. Never tamper with the ammeter and the cable while there is current flowing through. It may damage the ammeter. The following problems are related to the charging system; follow the instructions provided in the checking list to correct it if any one of the problems takes place. (1) The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction. (2) The charging voltage and current are too much higher than the standard values. The following problems are not related to the charging system; correct it if any by following steps indicate in the checking list. (1) The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rpm. - Bulbs used exceed their rate and consume too much power. - The replacement battery is aged and does not have enough capacity. (2) The charging voltage is normal, but the current is not. - The replacement battery is aged and does not have enough capacity. - Battery used does not have enough electricity or is over charged. - The fuse of the ammeter is blown. - The ammeter is improperly connected. (3) The charging current is normal, but the voltage is not. - The fuse of the voltmeter is blown. 17-6 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Inspection on regulator rectifier Remove the seat, rear carrier and rear fender. Disconnect two 3 pin couplers of the regulator rectifier. Inspection the rectifier coupler to the wire harness passes the condition. Item Check Points Standard Value Main switch connection Bl – B Battery Battery voltage (ON) connection Bl – B Battery voltage Charging coil B – B 0.1 ~ 0.5Ω If the readings measured are not normal, check parts in the circuit. If the parts are normal, then trouble is in the wiring. If there is nothing wrong with parts and wiring, replace the regulator rectifier. 17-7 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Ignition System Ignition circuit diagram C D I Unit B B Black R Red G Green W White Y Yellow L Blue BR/B Fuse 10A Main fuse 20A Spark plug Ignition coil Battery Main switch G Pulse generator C.D.I unit Disconnect connectors of the C.D.I unit. Check the following connectors as indicated in the table at the harness side. Item Points to check Result Main switch turn to “ON” position Br/Bl ~ B Battery voltage Pulse generator Bl/Y ~ G/R 50~170Ω Primary circuit G/R ~ B 2.9±10%Ω Ignition coil Secondary circuit TERMINAL-B ~ with no cap 15.0±10%Ω TERMINAL-B ~ with cap 20.0±10%KΩ 17-8 C D I Unit G/R B1/Y LG/R B B/W PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Inspection on Ignition Coil Disengage the connector of the ignition coil and the spark plug cap. Measure the resistance between the terminals of the primary winding. Standard resistance: 2.9Ω ± 10% Remove the cap from the spark plug and measure the resistance between the spark plug and the primary winding. Standard resistance: With no cap: 15.0Ω ± 10% With cap: 20.0±10%KΩ Ignition Coil Replacement Loosen the lock bolt and replace the ignition coil if necessary. Inspection of Pulse Generator Disconnect the coupler of the pulse generator and measure the resistance between the terminals of green/white and blue/yellow. Standard resistance: 50~170Ω Ignition coil Spark plug 17-9 PDF created with pdfFactory Pro trial version www.pdffactory.com

To this chapter contents 17. ELECTRICAL SYSTEM Starting System Starting circuit diagram C.D.I W B/W Fuse 15A B Main switch R Main fuse 30A F N R G/Y Brake switch Battery Change switch B1 Blue B Black R Red G Green W White Y Yellow BR Brown Starter switch Starter relay Starter motor G G/Y Brake light Inspection on starter relay Open the main switch. Press the brake. Push down the starter switch. If a sound of “ Looh Looh” is heard, it indicates the relay function normally. Remove the seat. Disconnect the negative cable terminal of the battery. Disconnect the cable positive terminal from the relay. Disconnect the positive cable of the starter motor. Disconnect the coupler of the relay. Connect an ohmmeter to the large terminal end. Connect the yellow/red cable to the battery positive terminal and the black / blue cable to the battery negative terminal. Check the continuity of the large terminal end. If there is no continuity, replace the relay. 17-10 Starter relay BR/B B1/W R B B PDF created with pdfFactory Pro trial version www.pdffactory.com

TGB TARGET 400 425 ATV Full Service & Repair Manual

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