Motorcycle Electrical TechBook (3rd Edition) Haynes
This book has been written to meet the needs of the practicing mechanic, both professional and amateur. No previous knowledge of electricity is assumed and all terms are explained in a glossary at the end of the manual. This book deals with the principles of how and why things work. Armed with an understanding of fundamentals it will be easier to follow developments which will surely take place in electrical equipment design. There may be a description of components which do not at the moment figure in actual production machines but, in the opinion of the author, may appear in the future.
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Modern motorcycles are remarkable examples of high technology and much of it is due to the electrical equipment designs of recent years. Electrical power requirements now demand generators of greatly increased output and because of the sensitivity of onboard electronic units, voltage regulators of high stability are needed. Not surprisingly these are also electronic!
The language of electronics is sometimes strange to beginners so a glossary of terminology is included as is emphasis on fault finding and testing. Readers are introduced to the transistor, Zener diode and thyristor (silicon controlled rectifier) and other devices, for these vital rugged components lie at the heart of most electronic circuits found on the motorcycle. A basic understanding of the on-board computer, which finds so many applications in ignition, fuelling and chassis systems is now essential and is described in sufficient detail for most purposes. Since there are still many older motorcycles on the road, vintage electrical equipment including dc dynamos and magnetos are included in this text.
Table Of Contents
Chapter 1 - The complete system
An overall view, Charging and storage, Fuelling, Ignition, Lighting and signaling, Starting (engine cranking).
Chapter 2 - Electrical Basics
Analogue and digital signals, Capacitance, Component symbols, CR charge and discharge, Electrical waveforms, Electromagnets, Electron flow (also known as current flow), Energy, work and power, Free electrons (conduction), Fundamental quantities, Further reading, Inductance in a dc circuit, Inductance, Integrated circuits, Light emitting diodes (LED), Light-dependent resistors (LDR), Motors and generators, Need you read this Chapter?, Ohm's law, Parallel connection, Permanent magnets, Photo-diodes and photo-transistors, Relays and solenoids, Resistance and Resistors, Semi-conductors, Sensors, Series and parallel circuits, Series connection, Temperature coefficient of resistance, Temperature measurement, Test instruments and measurements, The Atom - the source of electricity, The complete circuit, The Darlington Pair, The generator rule, The magnetic circuit, The Metal Oxide Field Effect Transistor (MOSFET), The motor rule, The operational amplifier, The p-n junction diode, The thyristor (SCR), The transistor, Wiring volt-drop, Zener diode.
Chapter 3 - Ignition and combustion
Combustion factors, Spark requirements for combustion, The catalytic converter, The four-stroke cycle, The four-stroke engine, The petrol (gasoline) engine, The two-stroke cycle, The two-stroke engine.
Chapter 4 - Ignition - Coil and battery
Coil ignition, Contact breaker service, Faulty capacitor symptoms, How does the capacitor assist ignition?, Ignition high voltage path, Ignition timing, Primary and secondary windings, Service work and fault finding, Spark energies, The Capacitor (condenser), The Contact breaker, The Ignition coil.
Chapter 5 - Ignition - Magnetos
Flywheel magneto, Further reading, Rotating-armature magneto, Rotating-magnet magneto, Servicing notes - rotating-armature and rotating-magnet magnetos, Servicing notes - flywheel magneto, The Magneto.
Chapter 6 - Ignition - Capacitor Discharge Ignition (GDI)
AC-CDI, Battery CDI, Capacitor Discharge Ignition (CDI), CDI with automatic ignition advance, Deficiencies of the Kettering ignition system, The electronic switch.
Chapter 7 - Ignition - Transistor and Digital Ignition
Basic TAC ignition circuit, Boyer Bransden aftermarket electronic ignition kits, Computerized ignition processing, Constant energy ignition, Digital ignition - speed control only, Digital ignition, Dwell control, Electronic ignition, Goodbye contact breakers!, Ignition advance - engine design, Ignition and fuelling, Mapped digital ignition, More about sensors, Pulse shaping, Transistor ignition development, Transistor-Assisted Contacts (TAC) coil ignition.
Chapter 8 - Fuel injection
Air metering, Bosch LE-Jetronic fuel injection, Fuel injection control, Fuel injection, Fuel metering.
Chapter 9 - Engine management
Bosch Motronic - BMW 16-valve models, Catalytic converter, Combined control of ignition and fuelling, Lambda exhaust closed-loop control, Open- and closed-loop control, Operation of the Lambda sensor, Performance mapping, The Triumph SAGEM system.
Chapter 10 - Spark plugs
Construction, Contact numbers, Corona discharge and flashover, Heat range, Ignition timing, Plug examination, Spark plug servicing, The Spark plug, Types of spark plug.
Chapter 11 - Charging - Direct current (dc) generators
Compensated Voltage Control (CVC), Complete control box, Control box settings, Converting ac to dc, Dynamo construction and overhaul, Electromagnetic generation, Electronic regulators, Introduction, Further reading and references, Temperature compensation, The Cut-out, The dc generator - excitation and control, Voltage regulation.
Chapter 12 - Charging - Alternators
Development of the alternator, Introduction, Principles of operation, Rectification - converting ac to dc, Single-phase and three-phase generation.
Part A: Flywheel alternators (Charge rate adjustment, Flywheel alternators - fault finding, Flywheel removal, Lighting and charging, Main/ignition switch faults, The flywheel alternator.)
Part B: Single-phase alternators (6 volt to 12 volt alternator conversion, Capacitor ignition circuit, Early Lucas alternators - 1953 to 1966, Emergency start (EMG), Later Lucas alternators, Lucas alternator color-coding, Single-phase alternator electronic control, Testing Lucas alternators, The Internal permanent magnet single-phase alternator.)
Part C: Three-phase alternators (Battery-excited alternators, Brushless alternator, Electronic regulators, Honda 8 diode alternator, Self-excited alternators, Testing three-phase alternators, The Three-phase alternator, Three-phase alternators with permanent magnet rotors, Three-phase alternators with electromagnetic rotors.)
Chapter 13 - Batteries
Battery capacity, Battery filling, Battery maintenance and fault finding, Charging MF batteries, Charging rate, Charging, overcharging and discharging, Cold cranking, Conventional lead-acid batteries, Filling MF batteries, Internal resistance, Maintenance-free (MF) batteries, Open-circuit voltage, Preparing a new battery for service (not MF types), Rules to extend battery life, Self discharge, Specific gravity, Sulfation, Testing MF batteries, The lead-acid battery, Why no topping-up of the MF battery? - The OXYGEN CYCLE.
Chapter 14 - Lighting and signaling
Brake lights, Bulbs - conventional tungsten filament types, Bulbs - quartz-halogen types, Bulbs - service life (tungsten types), Disadvantages of separate bulb and reflector, Horns, Introduction, Lens design aspects, Light units, Lighting faults, Lighting loads, Sealed beam unit, Self-cancelling turn signals, The Litronic headlamp, Turn signal circuits, Turn signal relays (flasher units).
Chapter 15 - Starter motors
Introduction, Starter lock-out circuits, Starter motor - operation, Starter motor - brush gear and commutator, Starter relay (solenoid), Starter-dynamo - description, Starter-dynamo - operation.
Chapter 16 - Circuits and system components
Part A: Wiring (Cable sizes, Cable volt-drop and current ratings, Fuses, Relays, Switches, Terminal markings, Wire color coding, Wiring diagram layout, Wiring diagrams and symbols, Wiring).
Part B: System components (Electrical connections, Electrical tool kit, Instrumentation and warning systems, Switches, sensors and sundries).
Chapter 17 - Braking and traction control (ABS and TCS)
Anti-lock Braking System (ABS), BMW ABS, Current designs, Honda ABS, Honda TCS, Principles of ABS braking, Yamaha ABS.
Chapter 18 - Testing and Fault finding
Part A: Basic meters and tests (Continuity testers, Test lights and buzzers, Multimeters, General testing, Ignition spark testing, Peak voltage testing).
Part B: Fault finding (Alternators, Contact numbers, dc generators/dynamos, Engine management, Fuel injection, Fault finding - general, Fuel pumps, General electrical problems, Ignition - CDI, Ignition - TCI, Horn, lamps and switches, Starter motors).
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