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Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)

Wiring Diagram (Europe, Korea, Hong Kong and Kuwait)

Wiring Diagram (United States, Canada, New Zealand and Malaysia)

Wiring Diagram (United States, Canada, New Zealand and Malaysia)

Wiring Diagram (Australia and South Africa)

Wiring Diagram (Australia and South Africa)

Wiring Diagram (EX650B Models)

Wiring Diagram (EX650B Models)

Precautions

There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below.

○^{Do not reverse the battery cable connections. This will}

burn out the diodes on the electrical parts.

○^{Always check battery condition before condemning other}

parts of an electrical system. A fully charged battery is a

must for conducting accurate electrical system tests.

○^{The electrical parts should never be struck sharply, as}

with a hammer, or allowed to fall on a hard surface. Such

a shock to the parts can damage them.

○^{To prevent damage to electrical parts, do not disconnect}

the battery cables or any other electrical connections

when the ignition switch is on, or while the engine is running.

○^{Because of the large amount of current, never keep the}

starter button pushed when the starter motor will not turn

over, or the current may burn out the starter motor wind- ings.

○^{Do not use a meter illumination bulb rated for other than}

voltage or wattage specified in the wiring diagram, as the

meter or gauge panel could be warped by excessive heat radiated from the bulb.

○^{Take care not to short the cables that are directly con-}

nected to the battery positive (+) terminal to the chassis

ground.

○^{Troubles may involve one or in some cases all items.}

Never replace a defective part without determining what

CAUSED the failure. If the failure was caused by some other item or items, they must be repaired or replaced, or the new replacement will soon fail again.

○^{Make sure all connectors in the circuit are clean and tight,}

and examine wires for signs of burning, fraying, etc. Poor

wires and bad connections will affect electrical system op- eration.

○^{Measure coil and winding resistance when the part is cold}

(at room temperature).

○^{Color Codes:}

BK: Black BL: Blue BR: Brown

CH: Chocolate DG: Dark Green

○^{Electrical Connectors}

G: Green GY: Gray

LB: Light Blue LG: Light Green O: Orange

P: Pink PU: Purple R: Red

W: White Y: Yellow

Female Connectors [A]

Precautions

Male Connectors [B]

Electrical Wiring

Wiring Inspection

_• Visually inspect the wiring for signs of burning, fraying, etc.

If any wiring is poor, replace the damaged wiring.

_• Pull each connector [A] apart and inspect it for corrosion, dirt, and damage.

If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.

_• Check the wiring for continuity.

○^{Use the wiring diagram to find the ends of the lead which}

is suspected of being a problem.

○^{Connect the hand tester between the ends of the leads.}

Special Tool - Hand Tester: 57001-1394

○^{Set the tester to the × 1 Ω range, and read the tester.}

If the tester does not read 0 Ω, the lead is defective. Re-

place the lead or the wiring harness [B] if necessary.

Battery Removal

_• Remove:

Seat (see Seat Removal in the Frame chapter)

_• Disconnect the negative (–) cable [A].

_• Slide out the positive (+) terminal cap [B] and then discon-

nect the positive (+) cable.

_• Remove the battery.

Battery Installation

_• Put the battery into the rear fender front.

_• Apply a light coat of grease on the terminals to prevent

corrosion.

_• Install the positive (+) cable [A] first.

_• Cover the positive (+) terminal with the cap [B].

_• Install the negative (–) cable [C].

Battery Activation

Electrolyte Filling

_• Make sure that the model name [A] of the electrolyte con- tainer matches the model name [B] of the battery. These

names must be the same.

Battery Model Name for EX650A/B: YTX12-BS

_• Place the battery on a level surface.

_• Check to see that the sealing sheet has no peeling, tears,

or holes in it.

_• Remove the sealing sheet.

NOTE

○^{The battery is vacuum sealed. If the sealing sheet has}

leaked air into the battery, it may require a longer initial

charge.

_• Remove the electrolyte container from the vinyl bag.

_• Detach the strip of caps [A] from the container and set

aside, these will be used later to seal the battery.

NOTE

○^{Do not pierce or otherwise open the sealed cells [B] of}

the electrolyte container. Do not attempt to separate

individual cells.

_• Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the

container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.

NOTE

○^{Do not tilt the electrolyte container}

_• Check the electrolyte flow.

If no air bubbles [A] are coming up from the filler ports, or

if the container cells have not emptied completely, tap the container [B] a few times.

_• Keep the container in place for 20 minutes or more. Don’t

remove the container from the battery until it’s empty, the

battery requires all the electrolyte from the container for proper operation.

_• Gently remove the container from the battery.

_• Let the battery sit for 30 minutes prior to charging to allow

the electrolyte to permeate into the plates for optimum

performance.

NOTE

○^{Charging the battery immediately after filling can}

shorten service life. Let the battery sit for at least 30

minutes after filling.