From the RFS book. Standard EXC
RFS Voltage Checks
Yellow wire feeds ac to the lights, white wire charges battery (via regulator/rectifier)Checking the generator output
Measuring conditions:
– cold engine– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery loaded (if installed) and light switch turned off– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
Check the generator output for voltage between the following cable colors:
– between yellow and brown (ground), loom disconnected
Multimeter display: 15 volts +/- 1 volt
– same measurement with loom connected
Multimeter display: 12 volts +/- 1 volt
– between white and brown (ground), loom disconnected
Multimeter display: 19 volts +/- 1 volt
– same measurement with loom connected
Multimeter display: 14 volts +/- 1 volt
NOTE: The black measuring lead of the peak voltage adapter must be
applied to the ground.
Check regulator rectifier output voltage cable colors yellow/red, regulator rectifier bk connected,
capacitor disconnected (if installed) and fuse bm removed:– between yellow/red and brown (ground)
Multimeter display: 14 volts +/- 1 volt
NOTE:
– The black measuring lead of the peak voltage adapter must be
applied to the ground.
– For facilitation of work, the regulator rectifier bk can be detached from
the frame.
Checking the voltage regulator-rectifier
A defect voltage regulator can cause different kinds of trouble:● No voltage in the circuit
In this case, the voltage regulator must be disconnected at idle speed.The voltage regulator is defect if the power consumers now workproperly.
If the power consumers are still not supplied with power, the switch,
the wiring harness or the ignition system must be checked for defects.● Excessive voltage in the circuit
The bulbs burn out. In this case the voltage regulator must bereplaced.
Checking the charging voltage
NOTE: The values stated below only apply to fully charged batteries(minimum charging level 90%).
– Start the engine and switch on the low beam.– Connect a voltmeter to both battery connections.– Accelerate the engine to a speed of 5000 rpm and read the voltage.Nominal value: 14.0 - 15.0 V
In the case of a significant deviation from the nominal value:
– Check the connector between the stator and the voltage regulatorrectifier
and the connector between the voltage regulator-rectifier and
the cable tree.
– Check the stator.
– Replace the voltage regulator-rectifier
Resistance checks:
Ignition CoilMeasure Cable colours Resistance
primary coil blue/white – ground 0.30 Ω ±15%
secondary coil blue/white – ignition wire 6.30 kΩ ±20%Stator
Ignition Measure cable colours ResistancePulser coil red – green 100 Ω± 20 Ω
4K-3B (EXC)
Exciter black/red – red/white 15 Ω± 3 Ω
Charge coil ground – yellow 0.65 Ω ± 0.15 Ω
white – yellow 0.16 Ω ± 0.03 Ω
Voltage checks
Measuring conditions:
– cold engine– seat and tank removed
– all connectors and the ground connection in a non-corroding condition, connectors tightly connected
– battery loaded (if installed) and light switch turned off– the gap between the rotor and pulse generator must be set to 0.75 mm
– compression release lever pulled
– kick the kick starter forcefully at least 5 times for each measurement
Check the pulse generator for an output signal – two-pin connector
with green and red cable colors:
– Apply the red measuring lead to the green cable and the black measuring lead to the red cable, disconnect the CDI unit
Multimeter display: 4.5 volts +/- 0.5 volt
– Same measurement with CDI unit connected
Multimeter display: 3 volts +/- 0.5 volt
Check the generator charging coil for ignition capacitor charge – two-pinconnector with black/red and red/white cable colors :
– Apply the red measuring lead to the black/red cable and the black measuring lead to the red/white cable, disconnect the CDI unit
Multimeter display: 30 volts (35 volts for 400 SX) +/- 5 volts
– Same measurement with CDI unit connected
Multimeter display: 200 volts +/- 10 volts
Check the primary voltage output for ignition coil control for output voltage (blue/white cable color):– Apply the red measuring lead to the black/white cable (ground) and the black measuring lead to the blue/white cable, CDI unit and ignition coil connectedMultimeter display: 200 volts +/- 10 volts
