Zongshen RX3: Electrical System Maintenance

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Electrical System Maintenance

When working with your motorcycle's electrical system, it is important to observe certain safety precautions to protect both yourself, and the motorcycle.

Battery Maintenance

Do not connect or disconnect any device when current is flowing, otherwise electrical components might be damaged. The RX3 battery is maintenance free (MF). To prolong the life of the battery, never exceed the recommended charging rate.

The RX3 comes equipped with an AGM (Absorbed Glass Mat) battery. The lead plates of this battery are separated by thin sheets of glass fiber impregnated with a solution of water and sulfuric acid. AGM batteries are very safe because they will not leak acid, even if placed upside down, or if the container is broken.

AGM batteries are permanently sealed. The user never needs to add water to the battery. Oxygen and hydrogen produced during battery charging are recombined to produce water, ensuring a very small water loss during the lifetime of the battery.

Your RX3 motorcycle comes equipped with a YTZ12S battery.

Battery Capacity: 11 Ah
210 C.C.A.
Charging Rate: 1.1 amps for 10 hours



REMOVING/INSTALLING THE BATTERY:

Always verify the ignition switch is in the OFF position before removing or installing the battery cables. Always remove the negative cable (-) first. Do not use tools which might come into contact with the positive (+) terminal and generate short circuits.

When installing the battery, always connect the positive (+) cable first. Make sure both cables are securely attached to the battery.

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Electrical Connections

The electrical system should be inspected periodically to verify proper connections and to watch for corrosion. Owners can check electrical continuity and resistance of electrical components with a digital multimeter.

Wiring Color Code

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Symbol Codes

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Electrical Charging System

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Charging Coil Resistance

The accuracy of a digital multimeter varies by model. Low-end meters are usually accurate within 1 percent of the correct value. The resistance of the charging coil should be from 0.07 to 1.5 ohms.

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Charging Voltage

Check the battery before troubleshooting any electrical problem.

Check the charging voltage. Place the multimeter on the 20 DCV scale and connect it to the battery terminals. Start the engine, keeping the idle speed at 1,600 rpm. The charging voltage should be between 13.90 to 14.40 volts.

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Charging Current

Verify all electrical accessories are turned off. Start the motorcycle. Verify the idle speed is 1,600 rpms. Set the digital multimeter to measure at least 10 amps of current (10 DCA).

Pull the main fuse and connect the multimeter between the two terminals of the fuse holder. Check the load current at an idle speed of 1,600 rpm. The charging current at 1,600 rpm should be 1.5 to 2.0 amps.

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CSC Cyclone RX3 Light Circuit

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Testing Relays and Diodes

Relay: An electrical device which controls a large current by switching an electromagnet.

Electromagnet: An electrical device which magnetizes a iron core by passing a low current through a coil wrapped around the core. The electromagnet can attract a platen to close a switch which completes a circuit passing a higher current.

Diode: Passes a current applied to the anode, but will not pass a current applied to the cathode.

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Engine Starting Circuit

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Testing the Starter Motor Relay

Verify the relay is wired properly. The cable from the battery must be connected to the relay terminal identified with the letter B (battery). The other terminal identified with the letter M (Motor) should be connected to the cable going to the starter.

The internal resistance of the starter relay should be 4 ohms.

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Spark Plug

Check the spark plug condition. Check the specification of the spark plug. Verify the spark plug is not damaged.

Measurements

Diameter: 10 mm
Hex Nut Width: 16 mm
Thread Length: 19 mm
Temperature: Mid-range
Flat Electrode
Resistor Plug

Electrode Gap: 0.7 to 0.9 mm

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Turn Signal Circuit

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Checking the Signal Flasher

1. Check the flasher cable for input voltage.
2. Check the voltage coming from the flasher to the switches on the gray cable.
3. Check the continuity of the turn signal switches.

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Brake Light Circuit