Page 18-1

18. LIGHTS/METERS/SWITCHES

SPECIFICATIONS

Headlight		12V 60W/55W	H4 / HB2 / 9003
Brake/taillight		12V 32/3 cp (27/8 W) x2	1157
Turn signal lights	Front	12V 32/3 cp (23/8 W) x2	1157
Turn signal lights	Rear	12 V 32 cp (23 W)	1156
License light		12V 4cp
Indicator lights	Turn signal	12V 3W	34908-KM1-671
	Neutral	12V 3W	34908-KM1-671
	High beam	12V 3W	34908-KM1-671
Meter light		12v 3.4W x1, 1.7W x2	34908-MG9-951 or 34908-MN8-700
Main Fuse		30A
Sub-fuse (fan, ignition, headlight, oil/neutral, brake/turn/horn, parking)		10A x6, 15A x1 (brake/turn/horn)
Fuel pump flow capacity/min		600cc (0.630 US qt, 0.528 Imp qt)

TORQUE VALUES

Radiator thermostatic switch	18 N.m (1.8 kg-m, 13 ft-lb) -- Apply sealant to threads
Oil Pressure Switch	12 N.m (1.2 kg-m, 9 ft-lb)-- Apply sealant to threads
Ignition switch mounting bolt	25 N.m (2.5 kg-m, 18 ft-lb)

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

Keep the temperature constant for 3 minutes to confirm continuity.
A sudden change of temperature will cause error temperature reading between the thermometer and switch.
Do not let the switch or thermometer touch the pan as it will give a false reading.
Immerse the switch in coolant up to its threads.

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

Do not over tighten the switch.

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.

Temperature 50°C
(122°F) 100°C
(212°F)
Resistance 130-180 Ohm. 25-30 Ohm.

WARNING

Wear gloves and eye protection.

NOTE

Coolant must be used as the heated liquid to check the function above 100°C (212°F).
You will get false readings if either the sensor or thermometer touches the pan.

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

Do not leave the temperature sensor wire grounded for longer than a few seconds or the temperature gauge will be damaged.

FUEL PUMP RELAY

WARNING

Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke or allow flames or sparks in the your work area or where gasoline is stored.

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.

ITEM STANDARD
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

ITEM	STANDARD
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

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

Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparkes in the work area or where gasoline is stored.

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.

Temperature	50°C (122°F)	100°C (212°F)
Resistance	130-180 Ohm.	25-30 Ohm.

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).