Motorcycle Repair: Battery Dead, motor carbon brushes, motorcycle batteries

Question
Hi Mark,
 I had some problems last year with my battery holding a charge after it had been sitting for a couple of weeks, and I would have to put the battery on a charger to get it to start.  Living in Canada winters get cold, so I took my battery out of my bike, and stored it indoors where it was warm.  When spring came I put my battery on the charger to charge it up, and when I hooked it back up to my bike, nothing.  It wouldn't even turn over.  My bike is a 1978 Kawasaki KZ1000A.  Would you say that since the bike started oaky in the fall, that mu battery is probably dead?  It is a 36 month battery, and was bought in June 2002.  What kind of battery would you suggest for this type of bike?


Thanks
Stacey

Answer
Hi Edward or Stacy,

Motorcycle batteries must be maintained regularly to keep them operating properly. Fluid levels must be maintained as the water part of the electrolyte evaporates.

During periods of non-use, batteries lack the constant discharge/recharge state with normal use and must be charged frequently during periods of storage to keep the battery healthy. If neglected, the battery may not even take a charge come spring.

Check the battery with a VOM (multi-meter) and a hydrometer designed for motorcycle batteries. Charge or replace the battery accordingly.

If problem persists, check for loose battery cables and heavy gauge cables from battery- to starter motor and chasis ground. Check all electrical connectors for corrosion and loose connections. Use dielectric grease on all connectors. Check switch contacts for corrosion and non-conductors such as webs and dead insects (believe it).

Check starter solenoid and starter motor carbon brushes.

Buy the service manual for procedures and specs. Visit "www.buykawasaki.com" and "www.bikebandit.com" to view microfiche parts on line.

I return tech information files via email. There was no email address as requested. See sample tech file pasted below.

Respectfully,
Mark Shively
Dayton, Ohio

p.s. I used to travel to Guelph, Ontario (Inglis Cycle Center) to purchase motorcycles.


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1977-78 Kawasaki KZ1000 Charging System Troubleshooter


1.) Battery Test (ignition off): Meter Scale: 20V DC, Meter Connections: Red test lead to Positive battery terminal, Black test lead to Negative battery terminal, Specifications: 12V min. No more than 1V drop, If up to spec proceed; if below spec, replace battery and retest.

2.) Battery Test (ignition on) (lights on): Meter Scale: 20V DC, Meter Connections: Red test lead to Positive battery terminal, Black test lead to Negative battery terminal, Specifications: 12V min. No more than 1V drop; If up to spec proceed, if below spec charge or replace battery and retest.

3.) Charging System Test: Meter Scale: 20V DC, Meter Connections: Red test lead to Positive battery terminal, Black test lead to Negative battery terminal, Specifications: 13.6V @ 4000 RPM; If above or below spec proceed to next test, if up to spec-charging system is OK.

4.) Alternator Test: Meter Scale: 120V AC, Meter Connections: Disconnect alternator output leads. Check AC output between all three alternator leads @4000 RPM, Specifications: 62V @ 4000 RPM; If up to spec proceed, if low-replace dyno armature and retest.

5.) Rectifier Test: Meter Scale: R x 1 Ohms, Meter Connections: (Disconnect Rectifier) (1) Connect Black test lead to ground wire from rectifier. With Red meter lead, check each Yellow rectifier lead for resistance. (2)  Connect Red test lead to ground wire from rectifier. With Black meter lead, check each Yellow rectifier lead for resistance. Specifications: Resistance in one direction, very little resistance when test leads are reversed (check service manual for ohm specs). If good proceed, if bad replace rectifier and retest.

6.) Regulator Test: Meter Scale: 12 Amp, Meter Connections: Connect meter in series with battery. Connect Black meter lead to ground, and Red meter lead to Negative terminal of battery. Kick start engine, and recheck meter reading @ 4000 RPM. CAUTION! Do not use electric starter. Specifications: 5.8A @ 4000 RPM; If up to spec proceed, if high or low-replace replace regulator and retest.

7.) Unregulated System Test: Meter Scale: 12 Amp, Meter Connections: (Disconnect regulator from system) Connect meter in series with battery. Connect Black meter lead to ground, and Red meter lead to Negative terminal of battery. Kick start engine, and recheck meter reading @ 4000 RPM. CAUTION! Do not use electric starter. Specifications: 9.5A @ 4000 RPM; If good, test complete. If bad, go back to #1 – Start over.


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Any well working charging system on a modern bike will produce a voltage over the battery terminals in between 13.5 VDC and 14.5 VDC, over the entire rev range. When you suspect a fault in the system, this is the first thing to check.
When you find that there is a problem, keep in mind that the no.1 fault in any charging system is bad connections.
Suspect any connection in the whole system. It's advisable to take off all fairing parts, the fuel tank and seat, and just disconnect all connectors you can find. Do this one at a time, and spray them with a contact cleaner. Before fitting the connector again, apply a small amount of dielectric grease to each connector. On the widely used bullet connectors, the ones used on many Japanese bikes for connecting single wires to each other, you should see if the male bullet connector needs a firm push when it slides into the female one. If not, use a pair of pliers to make the fit tighter in the female connector.
When you disconnect them one at a time, nothing can go wrong. You will see that the wires are color coded, so mistakes when refitting the connectors are almost impossible
The use of our universal fault finding chart is a good way of finding the fault in most of the charging-systems on motorcycles. Go through the tests step by step, following the procedure accurately. If you're not completely sure that you have the basic knowledge required with electrical systems on motorcycles, don't do the tests yourself, but find someone experienced in this field to help you.

Find the chart at our website:

www.electrexusa.com