Chapter 6, ELECTRICAL

Chapter 6, ELECTRICAL xjcdadmin Fri, 04/17/2020 - 10:43

Wiring Diagram

Wiring Diagram xjcdadmin Tue, 06/08/2010 - 01:09

 

1 A.C. Generator   2 Rectifier/Regulator   3 Main switch   4 Fuse "IGNITION" (10A)
5 Engine stop switch   6 Pickup coil   7
T.C.I. Unit   8 Ignition coil {No. 1, 4)   9 Ignition coil (No. 2, 3)
10 "FUEL" indicator light   11 Fuel sender   12 Tacho meter   13 Horn   14 Horn switch  
15 Flasher relay (Relay assembly)   16 Reed switch   17 Flasher switch   18 Flasher light (Front, Right)
19 Flasher light (Rear, Right)   20 "TURN" indicator light (Right)   21 "TURN" indicator light (Left)
22 Flasher light (Rear, Left)   23 Flasher light (Front, Left)   24 Oil level switch   25 "OIL" indicator light
26 Neutral switch   27 "NEUTRAL" indicator light   28 Brake switch   29 Tail/Brake light  
30 Fuse "SIGNAL" (15A)   31 Fuse "HEAD" (15A)   32 Meter light   33 Head light  
34 "HIGH BEAM" indicator light   35 Dimmer switch   36 Starter switch   37 Clutcn switch  
38 Starting circuit cut-off relay (Relay assembly)   39 Starter motor   40 Starter relay   41 Battery
42 Fuse "MAIN" (30A)   43 Sidestand switch   44 Sidestand relay   45 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 Fri, 04/17/2020 - 11:27

ELECTRICAL COMPONENTS 1

1 Fuse   2 Main switch   3 Front brake switch    4 TCI unit Main fuse Battery
5 Neutral switch   6 Rear brake switch   7 Sidestand switch   8 Oil level switch
9 Ignition coil

ELECTRICAL COMPONENTS 2

1 Horn   2 Sidestand relay   3 Diode assembly  
4 Relay assembly (Starting circuit cut-off relay, flasher relay)
5 Starter relay   6 Rectifier/Regulator   7 Starter motor
8 Fuel sender

Electric Starting System

Electric Starting System xjcdadmin Fri, 04/17/2020 - 11:45

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

Below circuit diagram shows starter circuit in wiring diagram.

.

3 Main switch

   4 Fuse "IGNITION" (10A)

   5 Engine stop switch

  
26 Neutral switch

   36 Starter switch

   37 Clutch switch

38 Starting circuit cut-off relay (Relay assembly)

   39 Starter motor

40 Starter relay

   41 Battery

   42 Fuse "MAIN" (30A)  
43 Sidestand switch   45 Diode

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

 

 

 

 

ELECTRIC STARTING SYSTEM

STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the starter motor, starter relay, starter safety unit, 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).

Battery Starter motor Starter relay Starter safety unit (Relay assembly) Starter switch Neutral switch

Sidestand switch Clutch switch Sidestand relay Tachometer Main switch Engine stop switch To ignitor switch

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.

 

 

 

STARTER SAFETY UNIT (Relay Assembly)

1.     Remove:

  Seat

  Fuel tank

  Relay assembly ®

2.     Check:

• Relay contacts Use 12V battery (§) and Pocket Tester (YU-03112). Out of specification — Replace relay.

Battery Connected: OH ® Battery disconnected: °° ©

DIODE

1.     Remove:

  Left side cover

   Diode ®

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 (OH) (Scale H x 1000) X : Discontinuity («>) (Scale ohm 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/Regulation

   3 Main switch


41 Battery

   42 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 Mon, 06/07/2010 - 22:56

IGNITION SYSTEM

 

3 Main switch

   4 Fuse "IGNITION" (10A)

   5 Engine stop switch

   6 Pickup coil

7 T.C.I. Unit

   8 Ignition coil (No. 1, 4)

   9 Ignition coil (No. 2, 3)

26 Neutral switch

   41 Battery

   42 Fuse "MAIN" (30A)

  
43 Sidestand switch

   44 Sidestand relay

   45 Diode

 

 

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

BP8ES (NGK) W24EP-U (NIPPONDENSO)

Electrode Gap 1 :

0.7 ~ 0.8 mm (0.028 - 0.031 in)

2. Install spark plug

Spark Plug: 20 Nm (2.0m*kg, 14ft-lb)

1 Finger tighten

2 Plug wrench tighten

Lighting System

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

LIGHTING SYSTEM

  

3 Main switch

   18 Flasher light {Front, Right)

   23 Flasher light (Front, Left)

29 Tail/Brake light

   31 Fuse "HEAD" (15A)

   32 Meter light

   33 Head light

34 "HIGH BEAM" indicator light

   35 Dimmer switch

   36 Starter switch

41 Battery

   42 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   10 "FUEL" indicator light   11 Fuel sender   13 Horn
14 Horn switch   15 Flasher relay {Relay assembly)   16 Reed switch
18 Flasher light (Front, Right)   19 Flasher light (Rear, Right)
20 "TURN" indicator light (Right)   21 "TURN" indicator light (Left)
22 Flasher light (Rear, Left)   23 Flasher light (Front, Left)   24 Oil level switch
25 "OIL" indicator light   26 Neutral switch   27 "NEUTRAL" indicator light
28 Brake switch   29 Tail/Brake light   30 Fuse "SIGNAL" 05A)


 

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.

 

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%

2 Battery (12V)

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

 

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 Thu, 05/14/2020 - 10:56

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