Motorcycle Electrical Maintenance
1.List of needed tools:
A.Set of pipe cleaners (found in tobacco shops).
B.Small package of cotton swabs.
C.Small brass bristle brush (found at hardware stores).
D.Set of welders tip cleaners(found at welding supply stores)or a set of jewelers files.
E.Selection of 400-600 grit sandpaper.
F.One can of electrical contact cleaner/preservative (The De-oxit brand at
www.de-oxit.com
is a good one).
G.Tube of dielectric grease as a water shield for connectors.(Optional, as some people see more problems with the grease acting more like an insulator).
H.An accurate multi-meter either digital or analog for voltage, current, and continuity checks (the digital meters may pick up “noise†from certain alternators and have fluctuating readings).
I.Self powered continuity light for basic continuity checks.
J.Battery charger rated for not more than 1 to 2 amp to charge the motorcycle battery( the battery tender brand is a good one at 1.25)
K.The motorcycle factory shop manual (FSM) with the wiring diagram.
L.Set of screwdrivers and wrenches for the various fasteners.
2.Corrosion on any electrical connection causes resistance and lowers the current flow. The green crud is a form of corrosion on brass/copper terminals.
3.All electrical connections must be clean and tight or intermittent operations will result,sometimes stranding the rider and can damage/destroy electrical components such as Alternator Stators,Batteries,Ignitors,Light bulbs,Switches and/or related wiring.
4.Battery cables can fail internally due to corrosion and appear serviceable.
5.The male bullet connector can be scrubbed with the brass brush while the female connector with the jewelers files or tip cleaner.Both should be spritzed/wiped with a pipe cleaner or rag moistened with contact cleaner.
6.Square and rectangular connectors must be disconnected from each other to be able to clean the contact surfaces. Again the use of files and or brass brush with a application of contact cleaner makes it operate as it should.Re-connect the male and female parts and do another.
7.The battery cables condition are an area few people think about but are very important. The positive(+) RED terminal and the negative(-) BLACK terminal must be clean and tight to both the battery and to their respective connections on the motorcycle. On most Kawasaki Motorcycles the negative battery cable goes either to the frame or engine while the positive battery cable connects to the electric starter solenoid.The other terminal on the solenoid connects to the starter motor.
8.If the battery cables must be replaced, use the appropriate gauge of wire for the current draw. Use flexible cable as solid wire will not bend into tight areas. Both 6 and 8 gauge can be purchased through electrical supply houses on the internet such as
www.waytekwire.com
, www.terminaltown.com,and
www.delcity.net
and have the correct wire or cable terminations. Welding cable is very flexible and makes excellent battery cables, it’s sold by the foot and can be purchased at welding supply stores.
9.OEM style electrical connectors can be purchased at:
www.easternbeaver
,
www.vintageconnections.com
,
www.vehicle-wiring-products.eu
, www.electricalconnection.com,and
www.z1enterprises.com
,
10.The starter solenoid function as a heavy duty relay having large contacts to close when the start signal is given from the handle bar “start switch†and the motor turns the engine over to run.
11.When the internal return spring on the starter fails/breaks due to metal fatigue or vibration, the engine will turn over(or crank) when the key has been removed and will continue until the positive battery terminal is dis-connected from the solenoid. Just like if the large terminals were bridged with a screwdriver.
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