Chapter 7, ELECTRICAL

Chapter 7, ELECTRICAL xjcdadmin Tue, 06/08/2010 - 01:09

XJ750XN CIRCUIT DIAGRAM

1 A.C. Generator
2 Rectifier/Regulator
3 Main switch
4 Fuse "FAN" (10A)
5 Thermo switch
6 Fan motor
7 Fuse "IGNITION" (10A)
8 "ENGINE STOP" switch
9 Pickup coil
10 T.C.I, unit
11 Ignition coil (#2, #3)
12 Ignition coil (#1, #4)
13 Sidestand relay
14 Sidestand switch
15 Tachometer
16 "FUEL" warning light
17 Fuel sender
18  Temperature meter
19  Thermo unit
20  Horn
21  "HORN" switch
22   Flasher relay (Relay assembly)
23   Flasher switch
24   Reed switch
25   Flasher light (Front, Right)
26   Flasher light (Rear, Right)
27  "TURN" indicator light (Right)
28   "TURN" indicator light (Left)
29   Flasher light (Rear, Left)
30   Flasher light (Front, Left)
31  "OIL LEVEL" indicator light
32  Oil level switch
3"NEUTRAL" indicator light
3Neutral switch
35 Fuse "SIGNAL" (15A)
36 Brake switch
37 Tail/Brake light
38 Clutch switch
39 Fuse "HEAD" (15A)
40 Meter light
41 Head light
42 "HIGH BEAM" indicator light
43 "LIGHTS" (Dimmer) switch
44 "START" switch
45 Starting circuit cut-off relay (Relay assembly) 
46 Starter motor 
47 Starter relay 
48 Battery
49 Fuse "MAIN" (30A) 
50 Diode assembly

COLOR CODE

0

Orange

Lg

Light green

B/Y

Black/Yellow

R

Red

Y/G

Yellow/Green

L/W

Blue/White

L

Blue

Y/R

Yellow/Red

L/G

Blue/Green

Br

Brown

Y/B

Yellow/Black

L/R

Blue/Red

B

Black

Y/L

Yellow/Blue

L/B

Blue/Black

Y

Yellow

Br/W

Brown/White

G/L

Green/Blue

W

White

R/B

Red/Black

G/R

Green/Red

G

Green

R/L

Red/Blue

G/Y

Green/Yellow

P

Pink

R/W

Red/White

G/W

Green/White

Dg

Dark green

R/Y

Red/Yellow

W/R

White/Red

Ch

Chocolate

B/R

Black/Red

W/B

White/Black

Gy

Gray

B/W

Black/White

W/G

White/Green

Sb

Sky blue

 

 

 

 

Electrical Components

Electrical Components xjcdadmin Tue, 06/08/2010 - 01:10

ELECTRICAL COMPONENTS 1

1 Ignition coil
2 Thermo switch
3 Thermo unit
4 Main switch
5 Sidestand switch
6 Battery
7 T.C.I, unit
8 Rectifier/Regulator
9 Oil level switch 
10 Rear brake switch 
11 Neutral switch

IGNITION COIL:
PRIMARY WINDING RESISTANCE: 2.7Ω ± 10%
SECONDARY WINDING RESISTANCE: 12kΩ±20%

BATTERY:
CAPACITY: 12V 14AH
SPECIFIC GRAVITY: 1.280

ELECTRICAL COMPONENTS 2

1 Horn
2 Sidestand relay
3 Diode assembly
4 Relay assembly {Flasher relay, Starting circuitcut-off relay) 
5 Starter switch 
6 Stator coil 
7 Field coil (Rotor)
8 Brush
9 Pickup coil assembly
10 Fuel sender

PICKUP COIL RESISTANCE: 120Ω ± 10%(B-Gy, G-O)

STATOR COIL RESISTANCE: 0.46Ω ± 10% (W-W)

FIELD COIL RESISTANCE: 4.0Ω ± 10% (Direct)

MINIMUM BRUSH LENGTH: 10 mm (0.39 in)

Electric Starting System

Electric Starting System xjcdadmin Tue, 06/08/2010 - 01:10

ELECTRIC STARTING SYSTEM

3 Main switch
7 Fuse "IGNITION" (10A)
8 "ENGINE STOP" switch
14 Sidestand switch
39 Fuse "HEAD" (15A)
44 "START" switch
45 Starting circuit cut-off relay (Relay assembly) 
46 Starter motor 
47 Starter relay 
48 Battery
49 Fuse "MAIN" (30A) 
50 Diode assembly

STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the starter motor, starter relay, starting circuit cutoff relay, and sidestand relay. If the engine stop switch and the main switch are both on, the starter motor can operate only if:
• The transmission is in neutral (the neutral switch is on.) 
• The sidestand is up (the sidestand switch is on) and the clutch lever is pulled in (clutch switch is on.)

When the transmission is in neutral.

When the sidestand is up and the clutch lever is pulled in.

When the engine is running.

1 Battery 
2 Starter motor 
3 Starter relay 
4 Starting circuit cut-off relay 
5 Starter switch 
6 Neutral switch
7 Sidestand switch
8 Clutch switch
9 Sidestand relay 
10 Tachometer 
11 Main switch
12 Engine stop switch 
13 To ignitor unit

 

Turn main switch to "ON" and engine stop switch to "RUN"

Transmission is

In neutral

In gear

Push starter switch Engine will start

Raise Sidestand and Pull in clutch lever

Ensure Sidestand is up

Push starter switch: Engine will start

Motorcycle can be ridden

 

TROUBLESHOOTING CHART

 

THE STARTER MOTOR DOES NOT OPERATE.

 

 

 

 

Connect "L/W" lead from the starter relay 1 to the battery negative (-) terminal 2 ; use a jumper lead.

The engine does not rev smoothly.

 

 

Recharge or replace the battery.

 

The engine does not operate.

 

Check the battery voltage (12V) on the "L/W" lead from the starter relay.

The engine operates.

Main and engine stop switches are turned to "ON".

If the starter relay does not click, check the starter relay and starter motor.

 

 

Connect "B/Y" lead to "ground" on the frame; use a jumper lead 1.

 

If the relay unit does not click, check the battery voltage (12V) on the "R/W" lead.

 

Check for an open or poor connection between the main switch and relay unit.

If the relay unit clicks, check the starter, sidestand, clutch and neutral switches. Replace switch(es) if necessary.

 

 

STARTING CIRCUIT CUTOFF RELAY (Relay Assembly) 

1. Remove:
• Seat
• Fuel tank

• Relay assembly 1

2. Check the relay contacts Use 12V battery 3 and Pocket Tester (90890-03112). Replace relayif out of specification.

Battery Connected: 0Ω 1  Battery Disconnected: 2

DIODE

1. Remove:
• Left side cover
• Diode 1

2. Check:
• Diode continuity/discontinuity 

Defective element(s) -> Replace the unit.

Checking element

Pocket tester connecting point

Good

(+) (red)

(-) (black)

D,

G

L/W

O

L/W

G

X

D2

Y

Sb

o

Sb

Y

X

D3

W/G

W

o

W

W/G

X

R

G

B/R

8.20

O: Continuity (0Ω) (Scale Ω x 1k) 
x : Discontinuity () (Scale Ω x 1)

NOTE:
The results "o" or "x" should be reversed according to the pocket tester polarity.

 

NEUTRAL SWITCH

1.  Remove:
• Left side cover
• Panel

2.  Check the neutral switch contact. Replace if out of specification.

Shift pedal 3

In neutral

In gear

Tester

∞Ω

1 Blue lead 
2 Ground

SIDESTAND SWITCH

1. Refer to neutral switch removal steps.

2. Check the sidestand switch 1 contact. Replace switch if out of specification.

Sidestand

Up 2

Down 3

Tester

∞Ω

CLUTCH SWITCH

1. Remove headlight unit

2. Check clutch switch contact. replace if out of specification. 

Clutch lever

Pull in

Not pull in

Tester

∞Ω

STARTER SWITCH 

1. Remove the headlight unit.

2. Check starter switch contact. Replace if out of specification.

 

Starter switch

ON

OFF

Tester

∞Ω

STARTER RELAY Inspection

Preparation steps:
• Disconnect starter motor red lead.
• Connect Pocket Tester leads to relay terminals.
•Turn main switch to "ON".
• Turn engine stop switch to "RUN".
• Move shift pedal to "NEUTRAL"

Push starter switch to "ON"

Relay clicks and tester reads

Relay does not click and tester does not read 0 Ω

OK

Measure resistance: 
Blue/White wire 1 to 
Battery side relay terminal 2

 

 

 

 

 

 

Resistance less than 1 Ω

Resistance more than 1 Ω

Check connections

Replace relay

 

Starter Motor

Starter Motor xjcdadmin Tue, 06/08/2010 - 01:10

STARTER MOTOR

1 O-ring 
2 Brush 
3 Armature 
4
Washer 
5 Circlip

Removal

Refer Chapter 3. "ENGINE DISASSEMBLY".

Inspection

1. Inspect commutator outer surface. Clean with 600 grit sandpaper if dirty. Check mica insulation between commutator segments and scrape mica to proper limits. Use a hacksaw blade that is ground to fit.

Mica Undercut 1 : 0.4 - 0.8 mm (0.02 - 0.03 in)

NOTE:
The mica insulation of commutator must be under-cut to ensure proper operation of commutator.

2. Measure the armature coil continuity 1. Replace or rewind starter motorif necessary.

Armature Coil: 0.014Ω ± 6% at 20°C (68° F)

Measure the armature coil insulation 2. Replace the starter motor if shorted.

3. Inspect:

• Front cover bearing 1
• Center and rear covers bushings 2

 Replace if damaged.

4. Measure the length of each brush length a and replace if less than minimum length.

Minimum Brush Length: 8.5 mm (0.34 in)

5. Check the brush spring pressure  and compare with new spring. Replace spring if weak.

 

Charging System

Charging System xjcdadmin Tue, 06/08/2010 - 01:10

CHARGING SYSTEM

 

1 A.C. Generator
2 Rectifier/Regulator
3 Main switch
48 Battery
49 Fuse "MAIN" (30A) 

 

CHARGING VOLTAGE INSPECTION

1. Remove seat

2. Connect Pocket Tester leads (to each battery terminal)

3.  Start the engine.

4.  Measure the charging voltage. Rev engine to approximately 3,000 r/min or more.

Charging Voltage: 14.2 ~ 14.8 V

TROUBLESHOOTING

 

Check voltage.    ◄   ◄   ◄   ◄
Not within specification      ▲

Inspect all connections

 Defective Correct.    ▲
OK      
 Measure the battery for voltage and specific gravity. 
Battery voltage: More than 12V
 Specific gravity: 1.280
Less than specification:    Recharge the battery.

OK

   

Remove the generator assembly and check the brush length, rectifier, and coil resistance.

Minimum brush length: 10 mm (0.39 in) 
Stator coil resistance: (White — White)
0.46H ± 10% at20°C(68°F) 
Field coil resistance: (Direct)
4.0ft ± 10% at20°C(68°F)

Less than specification: Replace the defective part(s).

OK

   
Replace rectifier/regulator.    

 

 

BATTERY

NOTE:
Replace the battery if:

•Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging.
•Sulfation of one or more cells occurs, as indicated by the plates turning white, or an accumulation of material exists in the bottom of the cell.
•Specific gravity readings after a long, slow
charge indicate one cell to be lower than the rest. 
•Warpage or buckling of plates or insulators is evident.

1 Terminal
2 Cap

3 Insulator
4 Separation plate
5 Negative electrode
6  Positive electrode

1.  Inspect the battery terminals and battery couplers. Clean off any corrosion. Tighten as required.

2.  Measure the specific gravity of battery fluid. Remove and recharge battery if less than 1.280

CAUTION:
To insure maximum battery performance be sure to:
 
• Charge a new battery before use.
• Maintain proper electrolyte level.
• Charge at proper current; 1.4 amps/10 hrs. or until the specific gravity reaches 1.280 at 20°C(68°F).

Failure to observe these points will result in a shortened battery life.

WARNING:
Battery electrolyte is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic.


Always follow these preventive measures: 
•Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. 
•Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): 
•SKIN - Flush with water. 
•EYES — Flush with water for 15 minutes and get immediate medical attention. 
• Drink large quantities of water or milk and follow with milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydrogen gas, therefore you should always follow these preventive measures: 

• Charge batteries in a well-ventilated area. 
• Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.) 
• DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

Battery Service Life

The service life of a battery is usually two to three years. Battery life may be shortened by poor maintenance.

Preparation steps:
• Keep battery topped off with distilled water.
• Keep battery charged.
• Do not overcharge battery.
• Do not allow battery to freeze.
• Do not fill with tap water or sulfuric acid containing impurities.
• Do not charge new battery using improper voltage or current.

Battery Storage

The battery should be stored if the motorcycles is not to be used for a long period. 

1. Remove the battery.

Battery storage and maintenance tips:
• Recharge the battery periodically.
• Store the battery in a cool, dry place.
• Recharge the battery before reinstalling.

Battery

YB14L

Electrolyte

Specific gravity: 1.280

Initial charging rate

1.4 amp for 10 hours (new battery)

Recharging rate

10 hours (or until specific gravity reaches 1.280)

Refill fluid

Distilled water (to maximum level line)

Refill period

Check once per month (or more often as required)

1 Field coil 
2 Stator 
3 Brush

GENERATOR ASSEMBLY

1.  Remove:
• Left side cover
• Panel

 

2.  Measure the stator coil resistance

Stator Coil Resistance: 0.46Ω ± 10% at 20°C (68°F) (W-W)

3.  Remove the A.C.G. cover

4.  Measure the field coil resistance

Field Coil Resistance: 4.0Ω ±10% at 20°C (68°F)

5.  Inspect the brush contact areas. Clean with 600 grit sandpaper if dirty.

6.  Measure each brush length 1. Replace if shorter than minimum.

Minimum Brush Length: 10 mm (0.39 in)

2 Wear indicator 

7. Inspect the brush springs Compare with new spring.

RECTIFIER/REGULATOR

1.  Remove:
• Left side cover
• Panel

2.  Check Rectifier/Regulator 1 diodes (Refer to the following table.) 

Defective element — Replace rectifier.


1 White 
2 White 
3 White 
4 Red
5 Ground 
6 Brown 
A Regulator 
B Rectifier

Checking 
element

Pocket tester 
Connecting point

Good

(+) 
(red)

(-)
(black)

D1

4

1

O

1

4

X

D2

4

2

O

2

4

X

D3

4

3

O

3

4

X

D4

1

5

O

5

1

X

D5

2

5

O

5

2

x

D6

3

5

O

5

3

x

O: Continuity X: Discontinuity ( )

CAUTION:
Do not overcharge rectifier or damage may result.
Avoid: 

• A short circuit
• Inverting + and -  battery leads
• Direct connection of rectifier to battery

NOTE:
The results "O" or "x" should be reversed according to the pocket tester polarity.

 

Ignition System

Ignition System xjcdadmin Tue, 06/08/2010 - 01:10

IGNITION SYSTEM

3 Main switch
7 Fuse "IGNITION" (10A)
8 "ENGINE STOP" switch
9 Pickup coil
10 T.C.I, unit
11 Ignition coil (#2, #3)
12 Ignition coil (#1, #4)
13 Sidestand relay
48 Battery
49 Fuse "MAIN" (30A) 

DESCRIPTION

This model is equipped with a battery operated, fully transistorized, breakerless ignition system. By using magnetic pickup coils, the need for contact breaker points is eliminated. This adds to the dependability of the system by eliminating frequent cleaning and adjustment of points and ignition timing. The TCI (Transistor Control Ignition) unit incorporates an automatic advance circuit controlled by signals generated by the pickup coil. This adds to the dependability of the system by eliminating the mechanical advancer. This TCI system consists of two units; a pickup unit and an ignitor unit.

OPERATION

The TCI functions on the same principle as a conventional DC ignition system with the exception of using magnetic pickup coils and a transistor control box (TCI) in place of contact breaker points.

Pickup Unit

The pickup unit consists of two pickup coils and a flywheel mounted onto the crankshaft. When the projection on the flywheel passes a pickup coil, a signal is generated and transmitted to the ignitor unit. The width of the projection on the flywheel determines the ignition advance.

1  Pickup coils

Ignitor Unit

This unit controls wave form, duty control, switching, electronic ignition advance, etc. The duty control circuit reduces electrical consumption by controlling the duration of the primary ignition current.

The ignitor unit 1 also has a protective circuit for the ignition coil. If the ignition switch is on and the crankshaft is not turning, the protective circuit interrupts the current flow to the primary coil after a few seconds. When the crankshaft is turning, however, the ignitor unit sends current to the primary coil.

1. Remove:
• Seat
• Left side cover
• Panel
• Ignitor unit 1

TROUBLESHOOTING

1. Start engine and warm-up a while, then turn it off.

2. Connect Electro Tester (90890-03021) 1
2  Spark plug wire  
3  Spark plug

3.  Start engine and increase spark gap until misfire occurs (Test at various rpm between idle and red line.)

CAUTION:
Do not run the engine in neutral above 6,000 rpm for more than 1 or 2 seconds.

Minimum Spark Gap: 6 mm (0.24 in)

4. If ignition system becomes inoperative or engine misfires see the troubleshooting chart below:

Troubleshooting Chart

Check entire ignition connections.

Poor connection

Correct.

 

▼ OK

Check battery voltage and specific gravity.

Low voltage/specific gravity

Recharge battery.

 

▼ OK

Check fuse and fuse connections.

Weak connection or open circuit

Correct connection or replace fuse.

 

▼ OK

Check ignition coil resistance (primary and secondary).

Primary: 2.7Ω ± 10%at20°C (68°F)

Secondary: 12 kΩ ± 20% at 20°C (68° F)

If other than specified

Replace ignition coil.

 

▼ OK

If other than specified

Replace pickup coil assembly.

 

 

Check pickup coil resistance.

Pickup coil: 120Ω ± 10% at 20°C (68°F)

▼ OK

Check operation of sidestand switch and relay.

Faulty

Check sidestand relay sidestand switch, diode and neutral switch.

 

 

▼ OK

TCI unit is faulty, replace unit.

IGNITION COIL

1. Remove the fuel tank

2. Disconnect the ignition coil leads 1

2 No. 2 and No. 3 cylinder ignition coil

3. Measure the primary coil resistance 

 

Primary Coil Resistance: 
O  to R/W  lead connector 
Gy  to R/W  lead connector 
2.7
Ω ± 10% at 20°C (68°F)

4. Measure secondary coil resistance 

 

Secondary Coil Resistance: 
12k
Ω ±20% at 20°C (68°F)

5. Connect:

 Electro tester 1
 Fully charged battery 2 (to ignition oil leads)
3 No. 1 (Rear) cylinder high tension cord 
4 Ground 
5 R/W lead 
6 O lead

6. Measure the ignition coil minimum spark gap Turn the spark gap adjuster and increase the gap to the maximum limit unless misfire occurs first. 

Minimum Spark Gap: 6 mm (0.24 in)

PICKUP COIL

1.  Remove:
• Left side cover
• Panel

2.  Disconnect pickup coil wires from TCI unit wires.

3. Measure the pickup coil resistance. Use pocket tester.

Pickup Coil Resistance:

No. 1 and No. 4 cylinder (O — B)
No, 2 and No. 3 cylinder (Gy - B)

120Ω ± 10% at 20°C (68°F)

SIDESTAND RELAY

1. Remove:

• Left side cover
 •Sidestand relay 1

2. Check the relay contacts

Use 12V battery 3 and Pocket Tester (90890-03112).

Battery Connected: 2 
Battery Disconnected: 0Ω  1

SPARK PLUG

1. Check condition and replace if burned or fouled. Clean and regap as necessary.

CAUTION:
Be sure to use plugs of proper type

D8EA (NGK) X24ES-U (NIPPONDENSO)

Electrode Gap 1 :

0.6 ~ 0.7 mm (0.024 - 0.028 in)

2. Install spark plug

Spark Plug: 17.5 Nm (1.75m*kg, 12.5ft-lb)

1 Finger tighten

2 Plug wrench tighten

Lighting System

Lighting System xjcdadmin Tue, 06/08/2010 - 01:10

LIGHTING SYSTEM

 

 

3 Main switch
25   Flasher light (Front, Right)
26   Flasher light (Rear, Right)
27  "TURN" indicator light (Right)
28   "TURN" indicator light (Left)
29   Flasher light (Rear, Left)
30   Flasher light (Front, Left)
37 Tail/Brake light
39 Fuse "HEAD" (15A)
40 Meter light
41 Head light
42 "HIGH BEAM" indicator light
43 "LIGHTS" (Dimmer) switch
44 "START" switch
48 Battery
49 Fuse "MAIN" (30A) 

 

 

TESTS AND CHECKS Headlight Troubleshooting

 

HEADLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING/HIGH BEAM DOES NOT OPERATION.

 

 

Check headlight.

Faulty

 

Replace.

 

Check head fuse.

Faulty 

 

Replace.

 

Measure voltage on brown wire from main switch ("ON" position).

Faulty 

 

Check dimmer switch, replace if necessary.

 

Measure voltage on blue/black wire from starter switch ("ON" position).

No voltage 

 

Check main switch, replace if necessary.

 

No voltage 

 

Check starter switch, if necessary.

 

Measure voltage at dimmer switch terminal.

An open or poor connection between headlight and dimmer switch terminal.

Measure voltage at headlight high beam or low beam terminal.

No voltage 

 

 

Poor ground or poor connection of headlight wiring.

 

Taillight Troubleshooting

TAILLIGHT DOES NOT COME ON WHEN ENGINE IS RUNNING.

 

 

 

Check taillight bulb.

Faulty

Replace.

▼ OK

 

 

Measure voltage on blue wire from main switch ("ON" position).

No voltage

Check main switch, replace if necessary.

▼ 12v

 

 

Measure voltage at taillight terminal.

No voltage.

An open or poor connection between taillight and main switch terminal.

12v

Poor ground or poor connection or taillight wiring.

 

 

 

Signal System

Signal System xjcdadmin Tue, 06/08/2010 - 01:10

SIGNAL SYSTEM

 

 

3 Main switch
15 Tachometer
16 "FUEL" warning light
17 Fuel sender
20  Horn
21  "HORN" switch
22   Flasher relay (Relay assembly)
23   Flasher switch
24   Reed switch
25   Flasher light (Front, Right)
26   Flasher light (Rear, Right)
27  "TURN" indicator light (Right)
28   "TURN" indicator light (Left)
29   Flasher light (Rear, Left)
30   Flasher light (Front, Left)
31  "OIL LEVEL" indicator light
32  Oil level switch
3"NEUTRAL" indicator light
3Neutral switch
35 Fuse "SIGNAL" (15A)
36 Brake switch
37 Tail/Brake light
44 "START" switch
48 Battery
49 Fuse "MAIN" (30A) 
50 Diode assembly

 

 

FLASHER LIGHT Troubleshooting

 

Flasher light and indicator light inoperative.

   

Check bulb.

Faulty

Replace.

 

▼OK

Measure voltage at flasher switch (Br/W wire and Y/R wire).

12V

Check flasher switch, replace if necessary.

 

No voltage

Check flasher relay, main fuse, signal fuse and battery.

Faulty and/or battery discharged .

Replace faulty parts and/or charge battery.

 

▼ OK

Check reed switch.

Defect

Replace.

 

▼ OK

Replace flasher relay (Relay assembly).

 

FLASHER RELAY (Relay Assembly)

NOTE
Flasher relay and self cancelling unit are included with relay assembly.

The flasher relay turns off the flashers. Generally the signal will cancel after either 10 seconds of operation or after the motorcycle has traveled 150 meters (490 feet), whichever is greater. At low speed, the cancelling is a function of distance; at high speeds, it's a function of both time and distance.

The flasher switch has three positions: L (left), OFF, and R (right). The switch lever will return to the "OFF" position after being pushed to L or R, but the signal will function. By pushing the lever in, the signal may be cancelled manually.

REED SWITCH

1.  Remove:

• Headlight unit
• Headlight body

2.  Disconnect the coupler

3.  Connect pocket tester

4.  Lift the front wheel and rotate the wheel by hand.

5. Measure reed switch resistance 

 

Reed Switch Resistance: About 7 Then return back OΩ or Ω when wheel is stopped

OIL LEVEL INDICATOR LIGHT 

1. Troubleshooting

 

Oil level indicator light inoperative

Check bulb

Faulty

Replace

OK

 

 

Measure voltage at oil level switch (Red/Black)

No voltage

Check diode, signal fuse, main switch, main fuse, and battery. Replace faulty parts.

12V

 

 

 

Check oil level switch, replace if necessary.

 

 

1 Red/Black lead 
2 Ground

FUEL WARNING INDICATOR LIGHT

1. Troubleshooting

 

Fuel warning indicator light inoperative

 

Check bulb

Faulty

Replace

OK

 

 

Measure voltage at fuel sender unit (Green).

No voltage

Check signal fuse, main switch, main fuse, and battery. Replace faulty parts.

12V

 

 

Check fuel sender, replace if necessary.

 

 

1 Green 
2 Black

FUEL SENDER UNIT

1.  Remove seat

2.  Fill the fuel tank (with gasoline)

3. Measure the fuel sender unit resistance. 

Fuel Sender Unit Resistance: 1.1 ±0.2kΩ @ 20°C (68°F)

NEUTRAL INDICATOR LIGHT

1. Troubleshooting

 

Neutral indicator light inoperative

 

Check bulb

Faulty

Replace

 

OK

Measure voltage at neutral switch (Sb wire)

No voltage

Check signal fuse, main switch, main fuse, and battery, Replace faulty parts.

12V

 

 

Check neutral switch. Replace if necessary.

 

 

1 Blue lead             
2 Ground

 

 

HORN

1. Check:

Check for:

Horn inoperative

12V on brown lead to horn

Good ground (horn/pink wire) when horn button is pressed

Faulty

Defective components — Replace. 

NOTE:
There are individual fuses for various circuits (See Complete Circuit Diagram)

2. Measure the horn resistance

Horn Resistance: 1.05Ω ± 10%

3. Adjust the volume. Turn the adjuster 1 in and out so that the volume is maximum at the maximum amperage.

2 Battery (12V)

Tester's lead wire

Maximum Amperage

Tester's range

Red lead

Black lead

Battery (+) lead

Horn lead and Battery (-) lead

2.0A

DC5A

BRAKE LIGHT

Check for:

Brake light inoperative

Defective bulb

12V on yellow lead to brake light

12V on brown lead to each brake light switch (Front and rear brake switch)

 

Switches

Switches xjcdadmin Tue, 06/08/2010 - 01:10

SWITCHES

Use Pocket Tester (90890-03112) on "Ohm x 1" scale to check the switches. Replace any "shorted" or opened element.

Main Switch

 

Switch position

Lead color

R

Br

L

ON

OFF

 

 

 

P

 

"ENGINE STOP" Switch

Switch position

Lead color

R/W

R/W

RUN

OFF

 

 

"START" Switch

Switch position

Lead color

L/W

B

R/Y

L/B

OFF

 

 

ON

 

 

"LIGHTS" (Dimmer) Switch

Switch position

Lead color

Y

L/B

G

HI

 

LO

 

"HORN" Switch

Switch position

Lead color

P

Ground or B

PUSH

OFF

 

 

'TURN" Switch

Switch position

Lead color

Dg

Br/W

Ch

Y/R

B

R

 

N

R

 

 

 

N

 

 

 

 

 

L

 

 

 

L

 

Oil Level Switch

Switch position

Lead color

R/B

Ground

ON

OFF

 

 

Front Brake Switch

Switch position

Lead color

Br

G/Y

ON

OFF

 

 

Rear Brake Switch

1 Switch body 
2 Adjusting nut

Switch position

Lead color

Y

Y

ON

OFF

 

 

 

Cooling System

Cooling System xjcdadmin Tue, 06/08/2010 - 01:10

COOLING SYSTEM

 

 

3 Main switch
4 Fuse "FAN" (10A)
5 Thermo switch
6 Fan motor
18  Temperature meter
19  Thermo unit
35 Fuse "SIGNAL" (15A)
48 Battery
49 Fuse "MAIN" (30A) 

 

 

TROUBLESHOOTING CHART (1)

 

TEMPERATURE GAUGE DOES NOT OPERATE.

   

Remove the fuel tank.

Turn the main switch "ON".

Disconnect the thermo unit connector. Check the battery voltage (12V) on Green/Red lead from the wire harness,

No

Check for an open or poor connection between the fuse "SIGNAL" and thermo unit connector.

Yes

   

Disconnect the thermo unit connector. Connect the Green/Red lead from the wire harness to "ground" on the frame; use a jumper lead 1 .

No
Replace the temperature gauge.

 

 

The temperature gauge needle will swing from "C" to "H".

 
   

▼ Yes 

Replace the thermo unit.

 

 

 

TROUBLESHOOTING CHART (2)

ELECTRIC FAN MOTOR DOES NOT OPERATE.

 

Disconnect the thermo switch 1 lead.

Check for the battery voltage (12V) on Brown lead from the wire harness. No
Check for an open or poor connection between the fuse "FAN" and thermo switch connector.
▼ Yes

Connect the Brown lead and Blue lead; use a jump lead 1 .

The fan motor operates. No
Replace the fan motor.
▼ Yes  
Replace the thermo switch.

 

THERMO UNIT AND THERMOMETER

Operation

The thermo unit has less resistance at higher temperatures and thus allows more current to pass through. When more current flows to the coil in the temperature gauge; the armature to which the needle is attracted by the increased magnetic field. In this way, the needle indicates the temperature.

1 Temperature gauge 
2 Red zone

Thermo Unit Inspection

1. Remove: 

• Thermo unit 1

CAUTION:
Handle the thermo unit with special care. Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced.

2. Check the thermo unit operation 

Thermo unit inspection steps:

• Immerse thermo-unit in water.

• Check continuity at indicated temperatures. Note temperatures while heating the water.

1 Temperature gauge 
2 Thermo unit 
3 Pocket tester 
4 Water

Water Temperature

50°C (122°F)

100°C (212°F)

120°C (248°F)

Resistance

156Ω

28.4Ω

17Ω

3.  Install the thermo unit 2

4.  Tighten the thermo unit

Thermo Unit 2 : 15 Nm (1.5m-kg, 11 ft lb)

CAUTION:
After replacing the thermo unit, check the coolant level in the radiator and also check for any leakage.

ELECTRIC FAN AND THERMO SWITCH

Operation

The electric fan will be switched ON or OFF according to the coolant temperature in the radiator.

1 Electric fan motor

NOTE:
The electric fan is controlled by the thermo switch when the main switch is "ON". Thus, under certain operating conditions, this fan may continue to run until the engine temperature has cooled down to about 98°C (208.4°F).

A THERMO SWITCH "ON" 
B COOLANT TEMPERATURE

The following problems may require repair or replacement of components

Component

Condition

Fan motor

Unsmooth operation 
Excessive vibration

Fan motor bracket 
Fan blades

Cracks

Securing bolts

Looseness

1 Fan

2 Electric fan motor

Thermo Switch Inspection

1. Remove the thermo switch 1

CAUTION:
Handle the thermo switch very carefully. Never subject it to strong shock or allow it to be dropped. Should it be dropped, it must be replaced.

2. Inspect the thermo switch operation

Thermo switch inspection steps:

• Immerse thermo switch in oil. 
• Check continuity as indicated temperatures. Note temperatures while heating the oil.

1 Temperature gauge 
2 Thermo switch 
3 Pocket Tester 
4 Oil

Test step

Oil temperature

Pocket Tester

x 1)

1

0- 98°C (32~208.4°F)

Discontinuity

2

More than 105°±3°C (more than 221.0 ±5.4°F)

Continuity

3*

105 to 98°C (221.0- 208.4°F)

Continuity

4*

less than 98°C (less than 208.4°F)

Discontinuity

Test 1 & 2: Heat-up tests 
Test 3* & 4*: Cool-down tests

3. Install the thermo switch 2

Thermo Switch 2 : 23 Nm (2.3 m-kg, 27 ft-lb)

CAUTION:
After replacing ther thermo switch, check the coolant level in the radiator and also check for any leakage.