5-2
Specifications
Electrical Connections
The electrical connections should be checked periodi-
cally for proper function. In case of an electrical fail-
ure, check fuse, connections (for tightness, corrosion,
damage), and/or bulb.
Switches
Each time the ATV is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition switch — engine will start (with brake
lever compressed).
B. Emergency stop switch — engine will stop.
C. Brakelight switch — brakelight will illuminate
with brake lever(s) compressed.
Battery
The battery is located under the seat.
After being in service, batteries require regular clean-
ing and recharging in order to deliver peak perfor-
mance and maximum service life. The following
procedure is recommended for cleaning and maintain-
ing a sealed battery. Always read and follow instruc-
tions provided with battery chargers and battery
products.
1. Remove the battery hold-down; then disconnect
the battery cables (negative cable first).
2. Remove the battery from the battery compartment;
then thoroughly wash the battery and battery com-
partment with soap and water.
NOTE: If battery posts, cable ends, or the battery
case has a build-up of white/green powder resi-
due, apply water and baking soda to neutralize
acid; then flush off with warm soapy water.
3. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
4. Using a multimeter, test the battery voltage. The
meter must read at least 12.5 DC Volts for a fully
charged battery.
NOTE: At this point if the meter reads as speci-
fied, the battery may be returned to service (see
step 8).
5. If the meter reads less than specified voltage,
charge the battery using the following guidelines.
A. When using an automatic battery charger,
always follow the charger manufacturer’s
instructions.
B. When using a constant-current battery charger,
use the following Battery Charging Chart.
IGNITION
Ignition Timing
28° BTDC (“F” Mark) @ 4000 RPM
Ignition Type
CDI
Spark Plug Type
CR7HSA
Spark Plug Gap
0.6-0.7 mm
(0.024-0.028 in.)
Spark Plug Cap
4725-5775 ohms
Ignition Coil
(primary)
Resistance
(secondary)
Less than 1 ohm (terminal to
terminal)
2830-3170 ohms (high tension -
plug cap removed - to ground)
MAGNETO
Timing Sensor
(peak voltage)
(resistance)
1.8-3.8 DC volts
(blue/yellow to ground)
80-160 ohms
(blue/yellow to ground)
Regulator/Rectifier
12.1-15.2 DC volts@ 3000 RPM
(white to black)
CDI/Ignition Coil
(peak voltage) 190-282 DC volts (black/yellow to
green)
Stator Coil
(no load) 13.5-16.5 AC volts @3000 RPM
(yellow to white)
Stator Coil Resistance
Less than 1 ohm (yellow to white)
Choke Circuit
(voltage) 3.5-4.5 AC volts (yellow to
green/black)
! WARNING
Anytime service is performed on a battery, the follow-
ing must be observed: keep sparks, open flame, ciga-
rettes, or any other flame away. Always wear safety
glasses. Protect skin and clothing when handling a
battery. When servicing battery in enclosed space,
keep the area well-ventilated.
CAUTION
Do not remove seal strip.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or cloth-
ing. Care must be taken whenever handling a battery.
CAUTION
Never exceed the standard charging rate.
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