Initial Charge

_• Place the strip [A] of caps loosely over the filler ports.

_• Newly activated sealed batteries require an initial charge.

Standard Charge: 1.2 A × 5  10 hours

If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery.

Kawasaki-recommended chargers Optimate III

Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9

If the above chargers are not available, use equivalent one.

NOTE

○^{Charging rates will vary depending on how long the}

battery has been stored, temperature, and the type of

charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. If it is not at least 12.8 V, repeat charging cycle.

_• After charging is completed, press down firmly with both hands to seat the strip of caps [A] into the battery (don’t

pound or hammer.). When properly installed, the strip of the caps will be level with the top of the battery.

NOTE

○^{To ensure maximum battery life and customer satisfac-}

tion, it is recommended the battery be load tested at

three times its amp-hour rating for 15 seconds.

Re-check voltage and if less than 12.8 V repeat the charging cycle and load test. If still below 12.8 V the battery is defective.

Precautions

1. No need of topping-up

No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that.

2. Refreshing charge.

If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Specifications).

When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.

3. When you do not use the motorcycle for months.

Give a refresh charge before you store the motorcycle and store it with the negative cable re- moved. Give a refresh charge once a month during storage.

4. Battery life.

If the battery will not start the engine even after several refresh charges, the battery has ex- ceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no prob- lem).

Interchange

A sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery.

Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.

Charging Condition Inspection

○^{Battery charging condition can be checked by measuring}

battery terminal voltage with a digital voltmeter [A].

_• Remove:

Seat (see Seat Removal in the Frame chapter)

Battery Cable Cap (see Battery Removal)

_• Disconnect the battery terminals.

_• Measure the battery terminal voltage.

NOTE

○^{Measure with a digital voltmeter which can be read one}

decimal place voltage.

If the reading is 12.8 V or more, no refresh charge is re- quired, however, if the read is below the specified, refresh charge is required.

Battery Terminal Voltage Standard: 12.8 V or more

Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C]

Refresh charge is required [D]

Refreshing Charge

_• Remove the battery [A] (see Battery Removal).

_• Do refresh charge by following method according to the

battery terminal voltage.

Terminal Voltage: 11.5  less than 12.8 V

Standard Charge 1.2 A × 5  10 h (see following chart) Quick Charge 5 A × 1 h

Terminal Voltage: less than 11.5 V Charging Method 1.2 A × 20 h

NOTE

○^{Increase the charging voltage to a maximum voltage of}

25 V if the battery will not accept current initially. Charge

for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 min- utes, replace the battery.

Battery [A]

Battery Charger [B] Standard Value [C] Current starts to flow [D]

_• Determine the battery condition after refresh charge.

○^{Determine the condition of the battery left for 30 minutes}

after completion of the charge by measuring the terminal

voltage according to the table below.

Criteria	Judgement
12.8 V or higher	Good
12.0  lower than 12.8 V	Charge insufficient → Recharge
lower than 12.0 V	Unserviceable → Replace

Alternator Cover Removal

_• Remove:

Left Center Fairing (see Center Fairing Removal in the

Frame chapter)

Alternator Lead Connector [A]

_• Place a suitable container under the alternator cover [A], and remove the cover bolts [B].

_• Pull the alternator cover outside.

Alternator Cover Installation

_• Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear

sides of the cover mount.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

_• Check that dowel pins [B] are in place on the crankcase.

_• Install a new gasket and the alternator cover.

_• Tighten:

Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

Stator Coil Removal

_• Remove:

Alternator Cover (see Alternator Cover Removal)

Holding Plate Bolt [A] and Plate Alternator Lead Grommet [B] Stator Coil Bolts [C]

_• Remove the stator coil [D] from the alternator cover.

Stator Coil Installation

_• Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them.

Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

_• Secure the alternator lead with a holding plate, and tighten the bolt.

○^{Apply a non-permanent locking agent to the threads of}

the holding plate bolt.

Torque - Alternator Lead Holding Plate Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)

_• Apply silicone sealant to the circumference of the alter-

nator lead grommet, and fit the grommet into the notch of

the cover securely.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

_• Install the alternator cover (see Alternator Cover Installa- tion).

Alternator Rotor Removal

_• Remove the alternator cover (see Alternator Cover Re- moval).

_• Remove the starter idle gear, torque limiter and shafts.

_• Wipe oil off the outer circumference of the rotor.

_• Hold the alternator rotor steady with the rotor holder [A],

and remove the rotor bolt [B] and washer.

Special Tools - Grip: 57001-1591