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Page 18-1

18. LIGHTS/METERS/SWITCHES

SERVICE INFORMATION18-1
TROUBLESHOOTING18-2
SWITCHES LOCATION18-2
HEADLIGHT18-3
IGNITION SWITCH/METER18-4
HANDLEBAR SWITCHES18-6
THERMOSTATIC SWITCH18-7
TEMPERATURE SENSOR18-7
TEMPERATURE GAUGE18-8
FUEL PUMP RELAY18-8
FUEL PUMP18-9
OIL PRESSURE SWITCH18-9
NEUTRAL SWITCH18-9
TURN SIGNAL RELAY18-10

SERVICE INFORMATION

WARNING




General


SPECIFICATIONS

Headlight12V 60W/55WH4 / HB2 / 9003
Brake/taillight12V 32/3 cp (27/8 W) x21157
Turn signal lightsFront12V 32/3 cp (23/8 W) x2 1157
Rear12 V 32 cp (23 W) 1156
License light12V, 8W, 4cp34616-568-671, 1195, 1155, 97
Indicator lightsTurn signal12V 3W34908-KM1-671
Neutral12V 3W34908-KM1-671
High beam12V 3W34908-KM1-671
Meter light12v 3.4W x1, 1.7W x234908-MG9-951 or 34908-MN8-700
Main Fuse30AATO type fuse
Sub-fusefan10A
Ignition10A
Headlight10A
Oil/neutral10A
Brake/turn/horn15A
Parking10A
Fuel pump flow capacity/min600cc (0.630 US qt, 0.528 Imp qt)

TORQUE VALUES

Radiator thermostatic switch18 N•m (1.8 kg-m, 13 ft-lb) — Apply sealant to threads
Oil Pressure Switch12 N•m (1.2 kg-m, 9 ft-lb)— Apply sealant to threads
Ignition switch mounting bolt25 N•m (2.5 kg-m, 18 ft-lb)


Page 18-2

TOOL

Common
T-40 Torx bit07703—0010100 — Equivalent commercially available in U.S.A.

TROUBLESHOOTING

No Lights Come On When Ignition Switch Is Turned On:

All Lights Come On, but Dimly, when Ignition Switch Is Turned ON

Headlight Beam Does Not Shift When HI-LO Switch Is Operated:

SWITCHES LOCATION




Page 18-3



HEADLIGHT

REMOVAL/INSTALLATION

Remove the two screws and headlight.



Disconnect the headlight connector and remove the rubber protector.



Remove the headlight retainer clip and replace the headlight bulb.

CAUTION



NOTE



Install the headlight in the reverse order of removal.


Page 18-4




IGNITION SWITCH/METER


IGNITION SWITCH INSPECTION

Check for continuity between the ignition switch connector terminals in each switch position.

Continuity should exist between the color coded wires as shown in the chart below.



REMOVAL

Disconnect the speedometer cable from the meter cover.
Remove the headlight.
Disconnect the meter harness connectors and ignition switch connectors in the headlight case.

Remove the mounting bolts and meters.



’88 Only:
Remove the mounting bolts and ignition switch.

After ’88:
Remove the (torx) mounting bolts using the special tool and the ignition switch.

TOOL:
T-40 Torx bit07703—0010100
or equivalent commercially available in U.S.A.

Page 18-5

METER BULB REPLACEMENT



Remove the meter cover mounting screws and cover.
Replace the burned bulb(s) as required.



Assemble the removed parts in the reverse order of disassembly.

INSTALLATION

After ’88:
Install the meters and ignition switch in the reverse order of removal.



After ’88:
Install the meters in the reverse order of removal.

Install the ignition switch and tighten the torx bolts using the special tool.

TOOL:
T-40 Torx bit07703—0010100
or equivalent commercially available in the U.S.A.

TORQUE: Ignition switch mounting bolt
25 N•m *2.5 kg-m, 18 ft-lb)

Page 18-6



HANDLEBAR SWITCHES

The handlebar switches (dimmer, turn signals, horn, starter, engine stop, etc.) must be replaced as assemblies.
Remove the headlight.

LEFT HANDLEBAR SWITCH

Disconnect the left handlebar switch connector (9P White).
And check for continuity between the terminals.
Continuity should exist between the color coded wires in each chart.







RIGHT HANDLEBAR SWITCH

Disconnect the right handlebar switch connector (9P Red) and check for continuity between the terminals.
Continuity should exist between the color coded wires as indicated in each chart.




Page 18-7


THERMOSTATIC SWITCH

The cooling fan motor is actuated by the thermostatic switch located in the bottom of the radiator.

If the fan motor does not start, disconnect the Black/Blue lead from the thermostatic switch and ground it with a jumper wire as shown.
Turn the ignition switch ON. The cooling fan motor should start running. If it does not start, check for battery voltage from the Black/Blue lead of the fan motor connector and ground with ignition switch ON.
If there is no voltage, check for a blown fuse, loose terminals or connectors, or an open circuit.
If there is voltage, inspect the thermostatic switch as follows: Remove the switch.
Connect one lead of an ohmmeter to the connector of the thermostatic switch and the other to the body.



Suspend the thermostatic switch in a pan of coolant (50-50 mixture) and check the temperatures at which the switch opens and closes.
Make sure that there is no continuity at room temperature and then gradually raise the coolant temperature. The switch should show continuity (close) at 93°-97°C (199°-207° F).

NOTE





Install a new O-ring on the switch.
Apply sealant to the switch threads and install it.
Tighten the switch to the specified torque.

TORQUE: 18 N•m (1.8 kg-m, 13 ft-lb)

NOTE





TEMPERATURE SENSOR

Remove the seat and fuel tank.
Disconnect the Green/Blue wire from the temperature sensor.
Check for continuity between the sensor body and ground.
There should be continuity.
If there is no continuity, check the thermostat housing for looseness and recheck. If there is still no continuity, remove. The temperature sensor from the thermostat housing.


Page 18-8


Suspend the temperature sensor in a pan of coolant over a heater and measure the resistance through the sensor as the coolant heats up.

Temperature50°C
(122°F)
100°C
(212°F)
Resistance130-180 Ohm.25-30 Ohm.

WARNING



NOTE



Replace the sensor if it is out of specification by more than 10% at either temperature.



TEMPERATURE GAUGE

Disconnect the wire from the temperature sensor and short it to ground.

Turn the ignition switch ON. The temperature gauge needle should move all the way to (H).

CAUTION



FUEL PUMP RELAY

WARNING



Remove the seat.
Check the sub-fuse (10 A).
Remove the relay from the rubber bracket and check the relay connector terminals for looseness and corrosion.

Inspect as follows:
Disconnect the connector and test the wires on the main harness side.

ITEMSTANDARD
Between Bl (+) and body ground (-)
with the ignition switch "ON"
Battery voltage should come.
Y/Bu wire between the pump
relay and spark unit
CONTINUITY
Bl/Bu wire between the pump
relay and fuel pump
CONTINUITY

HINT: Here is a full wiring diagram of how the fuel pump is powered


Page 18-9



FUEL PUMP

SYSTEM INSPECTION

Turn the ignition switch OFF.  Remove the seat and disconnect the fuel pump relay wire connnectors. Short the black and black/blue wire terminals with a wire jumper wire.

Disconnect the fuel tube from the T-joint near the carburetor and hold a graduated beaker under the fuel tube.

WARNING





Turn the ignition switch ON and let fuel flow into the beaker for 5 seconds, then turn the ignition switch OFF.
Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute.

FUEL PUMP FLOW CAPACITY:
600 cc (0.630 US qt. 0.528 Imp qt) /minutes at 10 V



OIL PRESSURE SWITCH

Make sure that the oil pressure warning light comes on with the ignition switch "ON".
If the light does not come on, inspect as follows:
Remove the drive sprocet cover.
Disconnect the oil pressure switch wire from the switch by removing the terminal screw. Short it to ground using a jumper wire.
Turn the ignition switch "ON".

The oil pressure warning light should come on.
If the light does not come on, check the bulb, sub-fuse (10A) and wires for a loose connection or an open circuit.
Start the engine and make sure that the light goes out.  If the light does not go out, check the oil presure (page 2-4).
If the oil pressure is normal, replace the oil pressure switch.  (page 2-4)


NEUTRAL SWITCH

INSPECTION

Remove the drive sprocket cover and disconnect the connector.
Check the neutral switch for continuity between the light green/red connector and body ground.
There should be continuity with the transmission in neutral and no continuity with the transmition in any gear.
If there is no continuity in neutral, remove the drive sprocket cover (page 8-2) and check the wire connection for an open circuit.


Page 18-10

TURN SIGNAL RELAY



Remove the seat and rear cowling (pages 13-25).
Remove the turn signal relay from the rubber bracket.

Check the turn signal circuit for proper connections before making this test.

Check each terminal as indicated below:

White/Green:D.C. 12 V Positive (+)
Green: D.C. 12 V Negative (-)
Gray:Turn signal wire of one side; connect
the other side to ground (frame).

Check the left and right turn signal operation.

If the turn signal relay fails this test, replace it.

HINT: Here is a full wiring diagram of how the turn signals and dash indicator are powered, and how to deal with LED replacement signals.