Checking the battery
* Voltmeter: Connect a voltmeter to the battery terminals, red wire to positive (+), black wire to negative (-). The voltage should be around 12.6 volts with the engine off and over 13.5 volts with the engine running.
* Load plug: Connect the load plug to the battery terminals. The fork will create a load within a few seconds. The voltage should remain above 10.5 volts during load.
Checking the starter
* Multimeter: Set the multimeter to resistance measurement mode. Check for good contact between the starter terminals and the battery. The resistance should be close to zero.
*Disconnection test: Pull the gear shift lever to neutral. Turn on the ignition and turn on the starter at the same time. The engine should start within a few seconds.
Generator check
* Voltmeter: Connect a voltmeter to the battery terminals as described above. With the engine running and headlights on, the voltage should be between 14 and 14.5 volts.
* Multimeter (Diode Test): Set the multimeter to diode test mode. Connect the black wire to the positive (+) terminal of the alternator and the red wire to the negative (-) terminal. The value on the display should be between 0.4 and 0.8 volts.
Checking the ignition system
* Spark Plugs: Remove the spark plugs and inspect them for signs of wear, damage or deposits. Measure the gap between the electrodes (usually 0.8 to 1.1 mm).
* Ignition coils: Check the coils for good connections, cracks or signs of overheating. Use a multimeter to check the resistance of the primary and secondary windings (see service manual for specific values).
* Ignition Module: Identify the ignition module and check for corrosion or damage to the wiring.
Checking the lighting
* Headlights and taillights: Turn on all lights and check that they are bright. Check for burnt out lamps or damaged lenses.
* Turn Signals and Hazard Lights: Turn on your turn signals and hazard lights to check if they are working properly.
* Brake lights: Have an assistant press the brake pedal while you check to see if the brake lights come on.
Checking fuses and relays
* Fuse Panel: Open the fuse panel and check the fuses for signs of burnt out (broken thread). Replace any blown fuses with fuses of the same rating.
* Relay Box: Locate the relay box and check the relay for signs of corrosion or damage. Remove the relay and shake it to check for switch sound. If noise is heard, the relay must be replaced.
Other electrical tests
* Checking the bus bars for current leakage: Disconnect the battery and connect a multimeter in current mode between the battery terminal and the disconnected cable. The value on the display should be close to zero.
* General Electrical Connections Inspection: Inspect all electrical connectors and wiring for corrosion, loose connections, or damaged insulation. Tighten loose connections and replace damaged components.