Signals

Model(s)

xjcdadmin Wed, 04/22/2009 - 01:16

SIGNAL SYSTEM

A. Circuit Diagram

Above circuit diagram shows only signal circuit in wiring diagram.

B. Signal System Tests and Checks

The battery provides power for operation of the horn, brake light, indicator lights and flasher light. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery water, or a defective charging system. See page 113 "CHARGING SYSTEM" for checks of battery and charging system. Also check fuse condition. Replace any "open" fuses. There are individual fuses for various circuits (see complete Circuit Diagram).

1. Horn does not work:

a. Check for 12V on brown wire to horn.

b. Check for good grounding of horn (pink wire) when horn button is pressed.

2. Brake light does not work:

a. Check bulb.

b. Check for 12V on yellow wire to brake light.

c. Check for 12V on brown wire to each brake light switch (front brake and rear brake switches).

3. Flasher light(s) do not work:

a. Check bulb.

b. Right circuit:

1) Check for 12V on dark green wire to light.

2) Check for ground on black wire to light assembly.

c. Left circuit:

1) Check for 12V on dark brown wire to light.

2) Check for ground on black wire to light assembly.

d. Right and left circuits do not work:

1) Check for 12V on brown/white wire to flasher switch on left handlebar.

2) Check for 12V on brown wire to flasher relay.

3) Replace flasher relay.

4) Replace flasher switch.

e. Check flasher self-canceling system. (Refer to flasher self-canceling system.)

4. Neutral light does not work:

a. Check bulb.

b. Check for 12V on sky blue wire to neutral switch.

c. Replace neutral switch.

6. Oil level warning light does not work:

a. Connect oil level switch (black/red wire) to ground. If light comes on, check for proper oil level.

b. If oil level is correct, replace oil level switch.

C. Self-Canceling Flasher System

1. Description:

The self-canceling flasher system turns off the turn signal after a period of time or distance involved in turning or changing lanes. Generally, the signal will cancel after either 10 seconds, or 150 meters (490 feet), whichever is greater. At very low speed, the function is determined by distance; at high speed, especially when changing speeds the canceling determination is a combination of both times and distance.

2. Operation:

The handlebar 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.

3. Inspection

If the flasher self-canceling system should become inoperative, proceed as follows:

a. Pull of the 6-pin connector from the flasher canceling unit, and operate the handlebar switch, if the signal operates normally in L, R, and OFF, the following are in good condition.

1) Flasher unit

2) Bulb

3) Lighting circuit

4) Handlebar switch light circuit

If (1) through (4) are in good condition, the following may be faulty:

1) Flasher canceling unit.

2) Handlebar switch reset circuit.

3) Speedometer sensor circuit.

b. Pull off the 6-pin connector from the flasher canceling unit, and connect a tester (ohms x 100 range) across the white/green and the black lead wires on the wire harness side. Turn the speedometer shaft. If the tester needle swing back and forth between 0 and ∞, the speedometer sensor circuit is in good condition. If not, the sensor to wire harness may be inoperative.

c. Pull the 6-pin connector from the flasher canceling unit. Check if there is continuity between the yellow/red lead wire on the wire harness side and the chassis.

Flasher switch OFF: ∞
Flasher switch L or R: 0 ohms

If the tester needle does not swing as indicated above, check the handlebar switch circuit and wire harness.

d. If no defect is found with the above three check-ups and the flasher canceling system is still inoperative, replace the flasher canceling unit.

e. If the signal flashes only when the handlebar switch lever is turned to L or R and it turns off immediately when the handlebar switch lever returns to center, replace the flasher canceling unit.

D. Switches

Switches may be checked for continuity with a pocket tester on the "ohm x 1" position. 1. Main switch

Switch Position	Wire Color
Switch Position	R	Br	L/Y
ON	0----	--0--	----0
OFF
LOCK
P (parking)	0----	------	----0

2. "ENGINE STOP" Switch

Switch	Wire Color
Position	R/W	R/W
RUN	0----	----0
OFF

3. "START" switch

Button Position	Wire Color
Button Position	L/W	Ground
PUSH	O-----	----O
OFF

4. "LIGHTS" (Dimmer) switch

Switch Position	Wire Color
Switch Position	Y	L/Y	G	G	L/G	Y/B
HI	0---	--O		0---	--O
LO		0---	--O		O----	--O

5. "TURN" switch

Switch Position	Wire Color
Switch Position	Ch	Br/W	Dg	Y/n	Ground
L	0---	--O		0---	--O
L > N	0---	--O
N > Push
R > N		O---	--O
R		O---	--O	0---	--O

6. "HORN" Switch

Button Position	Wire Color
Button Position	P	Ground
PUSH	O---	------O
OFF

E. Battery

1. Checking

If the battery shows the following defects, it should be replaced.

a. The battery voltage will not rise to a specific value or no gassing occurs in any cell even after many hours of charging.

b. Sulfation of one or more cells is indicated by the plates turning white or an accumulation of material in the bottom of the cell.

c. Specific gravity readings after a long slow charge indicate a cell to be lower than any others.

d. Warpage or buckling of plates or insulators is evident.

WARNING:
Battery fluid is poisonous and dangerous, causing severe burns, etc. Contains sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote:

EXTERNAL-FLUSH with water.

INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

2. The service life of a battery is usually 2 to 3 years, but lack of care as described below will shorten the life of the battery.

a. Negligence in keeping battery topped off with distilled water.

b. Battery being left discharged.

c. Over-charging with heavy charge.

d. Freezing.

e. Filling with water or sulfuric acid containing impurities.

f. Improper charging voltage or current on new battery.

3. If the motorcycle is not to be used for a long time, remove the battery and have it stored. The following instructions should be observed:

a. Recharge the battery periodically.

b. Store the battery in a cool, dry place.

c. Recharge the battery before reinstallation.

Battery	12N12A-4A-1
Electrolyte	Specific gravity: 1.280
Initial charging current	1.2 amp for 10 hours (new battery)
Recharging current	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, required)