KYMCO downtown 300i User manual

16. BATTERY/CHARGING SYSTEM
16-1
DOWNTOWN 300i
CHARGING SYSTEM LAYOUT
ACG
BATTERY REGULATOR/RECTIFIER

16. BATTERY/CHARGING SYSTEM
16-2
DOWNTOWN 300i
SERVICE INFORMATION
GENERAL INSTRUCTIONS
•The battery can be charged and discharged repeatedly. If a discharged battery is not used for a
long time, its service life will be shortened. Generally, the capacity of a battery will decrease
after it is used for 2～3 years. A capacity-decreased battery will resume its voltage after it is
recharged but its voltage decreases suddenly and then increases when a load is added.
•When a battery is overcharged, some symptoms can be found. If there is a short circuit inside the
battery, no voltage is produced on the battery terminals. If the rectifier won‘t operate, the voltage
will become too high and shorten the battery service life.
•If a battery is not used for a long time, it will discharge by itself and should be recharged every 3
months.
•A new battery filled with electrolyte will generate voltage within a certain time and it should be
recharged when the capacity is insufficient. Recharging a new battery will prolong its service life.
•Inspect the charging system according to the sequence specified in the Troubleshooting.
•Do not disconnect and soon reconnect the power of any electrical equipment because the electronic
parts in the regulator/rectifier will be damaged. Turn off the ignition switch before operation.
•It is not necessary to check the MF battery electrolyte or fill with distilled water.
•Check the load of the whole charging system.
•Do not quick charge the battery. Quick charging should only be done in an emergency.
•Remove the battery from the motorcycle for charging.
•When replacing the battery, do not use a traditional battery.
•When charging, check the voltage with an electric tester.
SPECIFICATIONS
Item Standard
Capacity 12V10AH
Voltage Fully charged 13.2V
(20℃) Insufficient charged < 12.3V
Battery
Charging current 1.2A* 5~10H
The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and
eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get
prompt medical attention
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16. BATTERY/CHARGING SYSTEM
16-3
DOWNTOWN 300i
TROUBLESHOOTING
No power Intermittent power
•Dead battery •Loose battery cable connection
•Disconnected battery cable •Loose charging system connection
•Fuse burned out •Loose connection or short circuit in
•Faulty ignition switch ignition system
Low power Charging system failure
•Weak battery •Loose, broken or shorted wire or connector
•Loose battery connection •Faulty regulator/rectifier
•Charging system failure •Faulty A.C. generator
•Faulty regulator/rectifier

16. BATTERY/CHARGING SYSTEM
16-4
DOWNTOWN 300i
BATTERY
REMOVAL
The battery is in the battery box below seat.
1. Remove the seat.
2. Remove the met-in box
3. Remove four screws and then the battery
retainer.
4. Pull battery out to expose the terminal
leads
5. Disconnect the negative (-) terminal lead
from the battery first, then disconnect the
positive (+) terminal lead.
6. Remove the battery from the battery box.
BATTERY INSTALLATION
Install in the reverse order of the removal.
VOLTAGE INSPECTION
Remove the battery cover.
Measure the battery voltage by using a
commercially available digital multimeter.
Voltage (20ºC/68ºF):
Fully charged: 13.0 ~ 13.2 V
Insufficient charged: < 12.3 V
When install the battery, first connect
the positive (+) cable and then negative
(-) cable to avoid short circuit.
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Screws
(-) Terminal(+) Terminal

16. BATTERY/CHARGING SYSTEM
16-5
DOWNTOWN 300i
BATTERY CHARGING
Remove the battery
Connect the charger positive (+) cable to the
battery positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-) terminal.
CHARGING CURRENT:
Standard: 1 .2A / 5~10 Hours
For battery charging, do not exceed the
charging current and time specified on the
battery. Using excessive current or extending
the charging time may damage the battery.
CHARGING VOLTAGE INSPECTION
Be sure that the battery is in good condition
before performing this test.
Start the engine and warm it up to the
operating temperature; stop the engine.
Connect the multimeter between the positive
(+) and negative (-) terminals of the battery.
To prevent short, make absolutely certain
which are the positive (+) and negative (-)
terminals or cable.
With the headlight on and turned to the high
beam position, restart the engine.
Measure the voltage on the multimeter when
the engine runs at 5000 rpm.
Standard:
Battery charging voltage 14 ~ 15V
Turn the power ON/OFF at the charger,
not at the battery terminals.
＊
Do not disconnect the battery or any
cable in the charging system without
first switching off the ignition switch.
Failure to follow this precaution can
damage the tester or electrical
t
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16. BATTERY/CHARGING SYSTEM
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DOWNTOWN 300i
REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the luggage box
Disconnect the regulator/rectifier connectors.
Check the connectors for loose contacts of
corroded terminals.
BATTERY WIRE
Measure the voltage between the Red/White
wire terminal and ground.
There should be battery voltage at all times.
GROUND WIRE
Check the continuity between the Green wire
terminal and ground.
There should be continuity at all times.
Regulator/Rectifie
r

16. BATTERY/CHARGING SYSTEM
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DOWNTOWN 300i
CHARGING COIL WIRE
Measure the resistance between each Yellow
wire terminals.
Standard: 0.4 ~ 0.6 Ω(20ºC/68ºF)
Disconnect the regulator/rectifier connector.
Check for continuity between each Yellow
wire terminal regulator/rectifier side and
ground.
There should be no continuity.
REMOVAL/INSTALLATION
Remove the side body cover.
Disconnect the regulator/rectifier connectors.
Remove the two bolts, regulator/rectifier.
Installation is in the reverse order of removal.
Connectors
Regulator/Rectifie
r