7.electrical System PDF

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ELEC
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 7-1
CHECKING SWITCH CONTINUITY................................................................7-3
CHECKING THE SWITCHES..........................................................................7-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-7

TYPES OF BULBS .................................................................................... 7-7
CHECKING THE CONDITION OF THE BULBS ....................................... 7-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................7-9
IGNITION SYSTEM ....................................................................................... 7-10

CIRCUIT DIAGRAM ................................................................................ 7-10
TROUBLESHOOTING ............................................................................7-11
ELECTRIC STARTING SYSTEM .................................................................. 7-15

CIRCUIT DIAGRAM ................................................................................ 7-15
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................ 7-16
STARTER MOTOR........................................................................................ 7-20

REMOVING THE STARTER MOTOR.....................................................7-21
DISASSEMBLING THE STARTER MOTOR...........................................7-21
CHECKING THE STARTER MOTOR .....................................................7-22
ASSEMBLING THE STARTER MOTOR................................................. 7-24
INSTALLING THE STARTER MOTOR ...................................................7-25
CHARGING SYSTEM....................................................................................7-26
CIRCUIT DIAGRAM ................................................................................ 7-26
LIGHTING SYSTEM ......................................................................................7-29

CIRCUIT DIAGRAM ................................................................................ 7-29
CHECKING THE LIGHTING SYSTEM....................................................7-32
SIGNALING SYSTEM ...................................................................................7-34

CIRCUIT DIAGRAM ................................................................................ 7-34
CHECKING THE SIGNALING SYSTEM ................................................. 7-36
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ELEC
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ELECTRICAL COMPONENTS ELEC
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
1 Fuse 8 Turn signal relay
2 Starter relay
3 Fuel sender
4 C.D.I. unit
5 Rectifier/regulator
6 Ignition coil
7 Horn
7-1
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ELECTRICAL COMPONENTS ELEC
1 Main switch
2 Fuse
3 Positive battery lead
4 Battery
5 Negative battery lead
6 Wire harness
7-2
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CHECKING SWITCH CONTINUITY ELEC
EAS00730
“∞” “0” CHECKING SWITCH CONTINUITY

Check each switch for continuity with the
pocket tester. If the continuity reading is incor-
rect, check the wiring connections and if nec-
essary, replace the switch.
“Ω×1”
CAUTION:
_
Never insert the tester probes into the cou-

pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
1
the leads.
Pocket tester
90980-03112
NOTE:
_
• Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
b and forth between the switch positions a few
times.
Br R
OFF
a The terminal connections for switches (e.g.,
ON
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
Br R The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
_
“ ” indicates a continuity of electricity

between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows

that:
There is continuity between red and brown
when the switch is set to “ON”.
7-3
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CHECKING SWITCH CONTINUITY ELEC
7-4
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CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
7-5
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CHECKING THE SWITCHES ELEC
1 Rear brake light switch
2 Horn switch
3 Dimmer switch
4 Turn signal switch
5 Front brake light switch
6 Light switch
7 Start switch
8 Main switch
9 Fuse
7-6
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CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for con-
tinuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs c is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs d and e are used for meter and indi-
cator lights and can be removed from their
respective socket by carefully pulling them
out.
7-7
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CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely

hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• Be sure to hold the socket firmly when

removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
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CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Check each bulb socket for continuity in the

same manner as described in the bulb section;
however, note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
1 Br B O
OFF R R W B W/R W/L
ON Br Br R Y
(BLACK) EAS00734
Br R W W W/L W/L
7 O O
R 6 Y Y/R W/R W/R 8 9
W W B
Y/R Y/R
B B 0
Br B
R B
W/L W/R W/R W/L
CIRCUIT DIAGRAM
B
R R/W Gy
Gy L/W L/W
2
IGNITION SYSTEM
Gy Gy
R R
5
R/W R/W
R R/W R/W L/W L/W Y/R
A D
R Gy
R L/W B Br
R L/W
B G/Y
L/W
3 4 B C (BLACK) (BLACK)
B L/W Y/R Y/R L/W

B L L/B B
Gy Br G/Y
B
B
B L/B
B
Br
7 - 10
G Br/W
Br Br
F
S Br
P Br/W
Br
H P L/B
U V W E
Br Br I J K
Dg Ch Ch Dg Dg P P Dg
B G G B Br/W B B Br/W
T Ch L/B L/B Ch
(RED) (RED)
G/Y
B
IGNITION SYSTEM
Ch Dg
Y G
G B Ch Dg
2 Fuse
3 Battery
G YY G
Ch Dg
Ch Dg L G/Y
8 C.D.I. unit
0 Spark plug
9 Ignition coil
X
1 Main switch
L
G G
7 A.C. magneto
P Q
ELEC
B B MN O
(BLACK) (BLACK)
R
–
Ch Dg B L L B
B Y G/Y
B B
Ch Dg Dg Ch
+
Ch Dg B
B B
B B B
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IGNITION SYSTEM ELEC
EAS00736 EAS00738
TROUBLESHOOTING
1. Fuse
The ignition system fails to operate (no • Check the fuse for continuity.
spark or intermittent spark). Refer to “CHECKING THE FUSE” in chap-
Check: ter 3.
1. fuse • Is the fuse OK?
2. battery
YES NO
3. spark plug
4. ignition spark gap
5. spark plug cap resistance Replace the fuse.
6. ignition coil resistance EAS00739
7. pickup coil resistance
8. main switch 2. Battery
9. wiring connections (of the entire ignition • Check the condition of the battery.
system) Refer to “CHECKING AND CHARGING
NOTE: THE BATTERY” in chapter 3.
_
• Before troubleshooting, remove the following Minimum open-circuit voltage

part(s): 12.8 V or more at 20 °C (68 °F)
1. seat
2. center cover • Is the battery OK?
3. rear panel
YES NO
4. right side cover
5. headlight assembly
• Troubleshoot with the following special • Refill battery fluid.
tool(s). • Clean the battery
terminals.
• Recharge or
Ignition checker replace the battery.
90890-06754
Pocket tester EAS00740
90890-03112 3. Spark plug

• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
Standard spark plug
C7HSA(NGK)
Spark plug gap
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
• Is the spark plug in good condition, is it of

the correct type, and is its gap within spec-
ification?
YES NO
Re-gap or replace
the spark plug.
7 - 11
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EAS00742 EAS00744
4. Ignition spark gap 5. Spark plug cap resistance

• Disconnect the spark plug cap from the • Remove the spark plug cap from the spark
spark plug. plug lead.
• Connect the ignition checker 1 as shown. • Connect the pocket tester (Ω × 1k) to the
2 Spark plug cap spark plug cap as shown.
• Set the main switch to “ON”. • Measure the spark plug cap resistance.
• Measure the ignition spark gap a.
• Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs. Ω×1k
Spark plug cap resistance

5 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?

Minimum ignition spark gap YES NO
6 mm (0.24 in)
• Is there a spark and is the spark gap within Replace the spark
specification? plug cap.
NO YES
The ignition system

is OK.
7 - 12
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EAS00746 EAS00748
6. Ignition coil resistance 7. Pickup coil resistance

• Disconnect the ignition coil connector from • Disconnect the A.C. magneto coupler from
the ignition coil terminal. the wire harness.
• Connect the pocket tester (Ω × 1) to the • Connect the pocket tester (Ω × 100) to the
ignition coil as shown. pickup coil terminal as shown.
Positive tester probe → terminal 1 Positive tester probe → white/blue 1
Negative tester probe → ignition coil base 2 Negative tester probe → white/red 2
B Y/R W W/R W/L

1
2 1
• Measure the primary coil resistance. • Measure the pickup coil resistance.
Primary coil resistance Pickup coil resistance
0.32 ~ 0.48 Ω at 20 °C (68 °F) 248 ~ 372 Ω at 20 °C (68 °F)
• Connect the pocket tester (Ω × 1k) to the • Is the pickup coil OK?
ignition coil as shown.
YES NO
Negative tester probe → terminal 1
Positive tester probe → spark plug lead 2
Replace the pickup
coil/stator assembly.
EAS00749
8. Main switch
• Check the main switch for continuity.
1 Refer to “CHECKING THE SWITCHES”.
2 • Is the main switch OK?
YES NO
• Measure the secondary coil resistance.
Secondary coil resistance Replace the main
5.68 ~ 8.52 kΩ at 20 °C (68 °F) switch.
• Is the ignition coil OK?
YES NO
Replace the ignition

coil.
7 - 13
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EAS00754
9. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES NO
Replace the C.D.I. Properly connect or

unit. repair the ignition
system’s wiring.
7 - 14
1 Br B O
OFF R R W B W/R W/L
ON Br Br R Y
(BLACK) EAS00755
Br R W W W/L W/L
7 O O
R 6 Y Y/R W/R W/R 8 9
W W B
Y/R Y/R
B B 0
Br B
R B
W/L W/R W/R W/L
CIRCUIT DIAGRAM
B
R R/W Gy
Gy L/W L/W
2
Gy Gy
R R
5
R/W R/W
A D
R Gy
R L/W B Br
R L/W
B G/Y
L/W
B L/W Y/R Y/R L/W

B L L/B B
ELECTRIC STARTING SYSTEM
Gy Br G/Y
B
B
B L/B
B
Br
7 - 15
G Br/W
Br Br
F
S Br
P Br/W
Br
H P L/B
U V W E
Br Br I J K
T Ch L/B L/B Ch
(RED) (RED)
G/Y
B
ELECTRIC STARTING SYSTEM
Ch Dg
Y G
G B Ch Dg
2 Fuse
3 Battery
G YY G
Ch Dg
Ch Dg L G/Y
X
C Start switch
1 Main switch
5 Starter relay
L
4 Starter motor
G G P Q
ELEC
B B MN O
(BLACK) (BLACK)
R
–
Ch Dg B L L B
B Y G/Y
B B
Ch Dg Dg Ch
E Rear brake light switch

D Front brake light switch
+
Ch Dg B
B B
B B B
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ELECTRIC STARTING SYSTEM ELEC
EAS00756
STARTING CIRCUIT CUT-OFF SYSTEM
8 OPERATION
If the main switch is set to “ON” (switch is
M closed), the starter motor can only operate if at
least one of the following conditions is met:
• The front brake lever is pulled to the handle-

7
bar (the front brake light switch is closed).
• The rear brake lever is pulled to the handle-
1 bar (the rear brake light switch is closed).
1 Battery
2 Fuse
2 3 Main switch
4 Front brake light switch
5 Rear brake light switch
3 6 Start switch
7 Starter relay
8 Starter motor
4 5
7 - 16
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EAS00757 EAS00738
TROUBLESHOOTING
1. Fuse
The starter motor fails to turn. • Check the fuse for continuity.
Check: Refer to “CHECKING THE FUSE” in chap-
1. fuse ter 3.
2. battery • Is the fuse OK?
3. starter motor
YES NO
4. starter relay
5. main switch
6. start switch Replace the fuse.
7. front brake light switch EAS00739
8. rear brake light switch
9. wiring connections 2. Battery
(of the entire starting system) • Check the condition of the battery.
NOTE: Refer to “CHECKING AND CHARGING
_
• Before troubleshooting, remove the following THE BATTERY” in chapter 3.

part(s): Minimum open-circuit voltage
1. seat 12.8 V or more at 20 °C (68 °F)
2. center cover
3. rear panel • Is the battery OK?
4. side cover (left and right)
YES NO
• Troubleshoot with the following special
tool(s). • Refill battery fluid.
• Clean the battery
terminals.
Pocket tester • Recharge or
90890-03112 replace the battery.
7 - 17
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EAS00758 EAS00761
3. Starter motor 4. Starter relay

• Connect the positive battery terminal 1 • Disconnect the starter relay coupler from
and starter motor lead 2 with a jumper the starter relay.
lead 3. • Connect the pocket tester (Ω × 1) and bat-
tery (12 V) to the starter relay terminal as
shown.
Positive battery terminal → blue/white 1
Negative battery terminal → gray 2
Positive tester probe → red 3
Negative tester probe → red/white 4
3
R
WARNING
_
R R/W
• A wire that is used as a jumper lead
Gy L/W
must have at least the same capacity or
R/W
more as that of the battery lead, other- 1 2
wise the jumper lead may burn.
• This check is likely to produce sparks, 4
therefore make sure nothing flammable • Does the starter relay have continuity
is in the vicinity. between red and red/white?
YES NO
• Does the starter motor turn?
YES NO Replace the starter

relay.
Repair or replace the
starter motor.
7 - 18
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EAS00749 EAS00766
5. Main switch 9. Wiring

• Check the main switch for continuity. • Check the entire starting system’s wiring.
Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”.
• Is the main switch OK? • Is the starting system’s wiring properly
YES NO
YES NO
Replace the main
switch. The starting system Properly connect or
EAS00764
circuit is OK. repair the starting
system’s wiring.
6. Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
YES NO
Replace the right

handlebar switch.
7. Front brake light switch

• Check the front brake light switch for conti-
nuity.
• Is the front brake light switch OK?
YES NO
Replace the front

brake light switch.
8. Rear brake light switch

• Check the rear brake light switch for conti-
nuity.
• Is the rear brake light switch OK?
YES NO
Replace the rear

brake light switch.
7 - 19
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STARTER MOTOR ELEC
EASF0767
STARTER MOTOR
1 Starter motor rear cover
2 Starter motor yoke
3 Armature
4 Bush set
5 Starter motor front cover assembly
BRUSH LENGTH LIMIT:

A
3.5 mm (0.14 in)
COMMUTATOR WEAR LIMIT:
B
21 mm (0.83 in)
MICA UNDER CUT:
C
1.5 mm (0.06 in)
ARMATURE COIL RESISTANCE:
D
0.032 ~ 0.039 Ω at 20 °C (68 °F)
7 - 20
– +
STARTER MOTOR ELEC
REMOVING THE STARTER MOTOR
1. Remove:
• footboard
Refer to “REMOVING THE FRONT COWL-
ING AND LEG SHIELD” in chapter 3.
2. Remove:
• battery
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
3. Remove:
• storage box
Refer to “FUEL TANK” in chapter 5.
• air filter case
Refer to “AIR FILTER CASE” in chapter 5.
4. Disconnect:
2 • battery negative lead 1
5. Remove:
• starter motor 2
DISASSEMBLING THE STARTER MOTOR

2 1. Remove:
3 • starter motor lead 1
• starter motor front cover bolts
(with washer and O-ring)
2. Remove:
• starter motor front cover 2
1 • washer 3
3. Remove:
1
• starter motor yoke 1
• O-rings 2
7 - 21
– +
STARTER MOTOR ELEC
4. Remove:
• armature 1
1
EAS00770
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt → Clean with 600-grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit

21 mm (0.83 in)
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.5 mm (0.06 in)
NOTE:
_
The mica of the commutator must be undercut

to ensure proper operation of the commutator.
7 - 22
– +
STARTER MOTOR ELEC
4. Measure:
• armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resis-
tances with the pocket tester.
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.032 ~ 0.039 Ω at 20 °C (68 °F)
Insulation resistance 2
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification,

replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit

3.5 mm (0.14 in)
7 - 23
– +
STARTER MOTOR ELEC
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

5.52 ~ 8.28 N
(563 ~ 844 gf, 19.87 ~ 29.80 oz)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
Damage/wear → Replace the defective
part(s).
EAS00772
b a b ASSEMBLING THE STARTER MOTOR

1
WARNING
_
Always use a new O-ring.
1. Install:
• washer
3 New (to armature)
2
• armature
(in starter motor front cover 1)
• O-rings New
(to starter motor yoke)
• starter motor yoke
• starter motor rear cover 2
NOTE:
_
Align the match mark a on the starter motor

yoke with the match marks b on the front and
starter motor rear cover.
• starter motor rear cover bolts

(with O-ring and washer)
• O-ring 3 New
(to starter motor front cover)
• starter motor lead
7 - 24
– +
STARTER MOTOR ELEC
INSTALLING THE STARTER MOTOR
1 For installation, reverse the removal proce-
dure.
1. Install:
• starter motor 1
• negative battery lead 2
2
• starter motor bolts
7 Nm (0.7 m · kg, 5.1 ft · lb)
T.
R.
7 - 25
EAS00773
1 Br B O
OFF R R W B W/R W/L
ON Br Br R Y
(BLACK)
CIRCUIT DIAGRAM
Br R W W W/L W/L
7 O
R 6 Y Y/R W/R W/R 8
CHARGING SYSTEM
W W
Y/R Y/R
B B
Br B
R B
W/L W/R W/R W/L
B
R R/W Gy
Gy L/W
2 L/W
Gy Gy
R R
7 - 26
R/W R/W
A
R Gy
R L/W
R L/W
L/W
3 4 B C
B L/W Y/R Y/R L/W
B L L/B B
Gy
B
B
B L/B
CHARGING SYSTEM
B
2 Fuse
3 Battery
Br
7 A.C. magneto
ELEC
G Br/W
Br
–
F
Br
+
– +
CHARGING SYSTEM ELEC
EAS00774 EAS00738
TROUBLESHOOTING
1. Fuse
The battery is not being charged. • Check the fuse for continuity.
Check: Refer to “CHECKING THE FUSE” in chap-
1. fuse ter 3.
2. battery • Is the fuse OK?
3. charging voltage
YES NO
4. charging coil resistance
5. wiring connections
(of the entire charging system) Replace the fuse.
NOTE:
_
EAS00739
• Before troubleshooting, remove the following

2. Battery
part(s):
1. seat • Check the condition of the battery.
2. center cover Refer to “CHECKING AND CHARGING
3. rear panel THE BATTERY” in chapter 3.
4. right side cover Minimum open-circuit voltage
• Troubleshoot with the following special 12.8 V or more at 20 °C (68 °F)
tool(s).
• Is the battery OK?
Engine tachometer YES NO

90890-03113
Pocket tester
90890-03112 • Refill battery fluid.
terminals.
• Recharge or
replace the battery.
7 - 27
– +
CHARGING SYSTEM ELEC
EAS00775 EAS00776
3. Charging voltage 4. Charging coil resistance

• Connect the engine tachometer to the • Disconnect the A.C. magneto coupler from
spark plug lead. the wire harness.
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (Ω × 1) to the
battery as shown. charging coil as shown.
Positive tester probe → Positive tester probe → white 1
positive battery terminal 1 Negative tester probe → black 2
Negative tester probe →
negative battery terminal 2
B Y/R W W/R W/L
2 1
• Measure the charging coil resistances.
Charging coil resistance
• Start the engine and let it run at approxi- 0.32 ~ 0.48 Ω at 20 °C (68 °F)
mately 5,000 r/min.
• Measure the charging voltage. • Is the charging coil OK?
Charging voltage YES NO
14 V at 5,000 r/min
NOTE:
_
Replace the pick up
Make sure the battery is fully charged. coil/stator coil assem-
bly.
EAS00779
• Is the charging voltage within specifica-
tion? 5. Wiring
NO YES • Check the wiring connections of the entire

charging system.
The charging circuit • Is the charging system’s wiring properly
is OK. connected and without defects?
YES NO
Replace the rectifier/ Properly connect or

regulator. repair the charging
system’s wiring.
7 - 28
1 Br B O
OFF R R W B W/R W/L
ON Br Br R Y EAS00780
(BLACK)
2 Fuse
W W W/L W/L
3 Battery
Br R O O
R 6 Y Y/R
7 W/R W/R 8 9
R Headlight
W W B
U Meter light
Y/R
B Light switch
1 Main switch
Y/R
B B 0
7 A.C. magneto
Br B
R
O Tail/brake light
J Dimmer switch
B
W/L W/R W/R W/L
CIRCUIT DIAGRAM
B
R R/W Gy
Gy L/W L/W
2
Gy Gy
LIGHTING SYSTEM
V High beam indicator light

R R
5
R/W R/W
A D
R Gy
R L/W B Br
R L/W
B G/Y
L/W
B L/W Y/R Y/R L/W

B L L/B B
Gy Br G/Y
B
B
B L/B
B
Br
7 - 29
G Br/W
Br Br
F
S Br
P Br/W
Br
H P L/B
U V W E
Br Br I J K
T Ch L/B L/B Ch
(RED) (RED)
G/Y
B
Ch Dg
Y G
LIGHTING SYSTEM
G B Ch Dg
G YY G
Ch Dg
Ch Dg L G/Y
X
L
G G P Q
B B MN O
R
ELEC
(BLACK) (BLACK)
Ch Dg B L L B
B Y G/Y
B B
–
Ch Dg Dg Ch
Ch Dg B
B B
B B B
+
– +
LIGHTING SYSTEM ELEC
EAS00781 EAS00738
TROUBLESHOOTING
1. Fuse
Any of the following fail to light: head- • Check the fuse for continuity.
light, high beam indicator light, taillight Refer to “CHECKING THE FUSE” in chap-
or meter light. ter 3.
Check: • Is the fuse OK?
1. fuse
YES NO
2. battery
3. main switch
4. light switch Replace the fuse.
5. dimmer switch EAS00739
6. lighting coil resistance
7. wiring connections 2. Battery
(of the entire lighting system) • Check the condition of the battery.
NOTE: Refer to “CHECKING AND CHARGING
_
• Before troubleshooting, remove the following THE BATTERY” in chapter 3.

part(s): Minimum open-circuit voltage
1. seat 12.8 V or more at 20 °C (68 °F)
2. center cover
3. rear panel • Is the battery OK?
4. right side cover
YES NO
tool(s). • Refill battery fluid.
terminals.
Pocket tester • Recharge or
90890-03112 replace the battery.
EAS00749
3. Main switch
• Is the main switch OK?
YES NO
Replace the main

switch.
7 - 30
– +
EAS00783 EAS00776
4. Light switch 6. Lighting coil resistance

• Check the light switch for continuity. • Disconnect the A.C. magneto coupler from
Refer to “CHECKING THE SWITCHES”. the wire harness.
• Is the light switch OK? • Connect the pocket tester (Ω × 1) to the
lighting coils as shown.
YES NO
Positive tester probe → yellow/red 1
Negative tester probe → black 2
The light switch is
faulty. Replace the
right handlebar
switch.
EAS00784
5. Dimmer switch
B Y/R W W/R W/L
• Check the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES”. 2 1
• Is the dimmer switch OK?
• Measure the lighting coil resistances.
YES NO Lighting coil resistance
0.24 ~ 0.36 Ω at 20 °C (68 °F)
The dimmer switch is • Is the lighting coil OK?
faulty. Replace the
left handlebar switch. YES NO
Replace the pickup

coil/stator coil
assembly.
EAS00787
7. Wiring
• Check the entire lighting system’s wiring.
• Is the lighting system’s wiring properly
YES NO
Check the condition Properly connect or

of each of the lighting repair the lighting
system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.
7 - 31
– +
EAS00788
CHECKING THE LIGHTING SYSTEM High beam indicator light
1. The headlight and the high beam indicator Positive tester probe → yellow 4
light fail to come on. Negative tester probe → black 5
1. Headlight bulb and socket

Y
• Check the headlight bulb and socket for
AC20V 4
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the headlight bulb and socket OK? Br
5 Dg Ch
YES NO B G
• Set the main switch to “ON”.

Replace the head- • Start the engine.
light bulb, socket or • Set the light switch to “ ”.
both. • Set the dimmer switch to “ ” or “ ”.
• Measure the voltage (AC 12 V) of green 1
2. Voltage or yellow 2 on the headlight connector
• Connect the pocket tester (AC 20 V) to the (wire harness side) and yellow 4 on the
headlight connectors and high beam indi- meter assembly connector.
cator light connector and coupler as • Is the voltage within specification?
shown.
YES NO
Headlight
Positive tester probe →
green 1 or yellow 2 This circuit is OK. Replace the rectifier/
Negative tester probe → black 3 regulator.
È When the dimmer switch is set to “ ”

É When the dimmer switch is set to “ ”
7 - 32
– +
EAS00789 EAS00790
2. The meter light fails to come on. 3. The tail/brake light fails to come on.
1. Meter light bulb and socket 1. Tail/brake light bulb and socket
• Check the meter light bulb and socket for • Check the tail/brake light bulb and socket
continuity. for continuity.
Refer to “CHECKING THE BULBS AND Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. BULB SOCKETS”.
• Are the meter light bulb and socket OK? • Are the tail/brake light bulb and socket
OK?
YES NO
YES NO
Replace the meter
light bulb, socket or Replace the tail/
both. brake light bulb,
socket or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the 2. Voltage
meter light coupler (wire harness side) as • Connect the pocket tester (AC 20 V) to the
shown. tail/brake light coupler (wire harness side)
Positive tester probe → brown 1 as shown.
Negative tester probe → black 2 Positive tester probe → blue 1
1
Br Br
1 2
Ch Dg Dg Ch
B L L B
G B B G Y G/Y
Ch Dg Dg Ch
2

• Set the light switch to “ ”. • Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown • Start the engine.
1 on the meter light coupler (wire harness • Set the light switch to “ ”.
side). • Measure the voltage (AC 12 V) of blue 1
• Is the voltage within specification? on the tail/brake light coupler (wire har-
ness side).
YES NO • Is the voltage within specification?
YES NO
This circuit is OK. The wiring circuit
from the main switch
to the meter light This circuit is OK. Replace the rectifier/
coupler is faulty and regulator.
must be repaired.
7 - 33
1 Br B O
OFF R R W B W/R W/L
ON Br Br R Y EAS00793
(BLACK)
G Horn
2 Fuse
W W W/L W/L
3 Battery
Br R O O
R 6 Y Y/R
7 W/R W/R 8 9
W W B
T Fuel gauge
Y/R
I Horn switch
1 Main switch
Y/R
X Fuel sender
B B 0
Br B
R
O Tail/brake light
B
W/L W/R W/R W/L
F Turn signal relay

CIRCUIT DIAGRAM
K Turn signal switch

B
R R/W Gy
Gy L/W
L/W
2
E Rear brake light switch

Gy
R
Gy
R
D Front brake light switch
W Turn signal indicator light

M Rear turn signal light (left)
P Front turn signal light (left)

SIGNALING SYSTEM
Q Front turn signal light (right)

N Rear turn signal light (right)
5
R/W R/W
A D
R Gy
R L/W B Br
R L/W
B G/Y
L/W
B L/W Y/R Y/R L/W

B L L/B B
Gy Br G/Y
B
B
B L/B
B
Br
7 - 34
G Br/W
Br Br
F
S Br
P Br/W
Br
H P L/B
U V W E
Br Br I J K
T Ch L/B L/B Ch
(RED) (RED)
G/Y
B
Ch Dg
Y G
SIGNALING SYSTEM
G B Ch Dg
G YY G
Ch Dg
Ch Dg L G/Y
X
L
G G P Q
B B MN O
R
ELEC
(BLACK) (BLACK)
Ch Dg B L L B
B Y G/Y
B B
–
Ch Dg Dg Ch
Ch Dg B
B B
B B B
+
– +
SIGNALING SYSTEM ELEC
EAS00794 EAS00738
TROUBLESHOOTING
1. Fuse
• Any of the following fail to light: turn • Check the fuse for continuity.
signal light, brake light or an indicator Refer to “CHECKING THE FUSE” in chap-
light. ter 3.
• The horn fails to sound. • Is the fuse OK?
Check:
YES NO
1. fuse
2. battery
3. main switch Replace the fuse.
4. wiring connections EAS00739
(of the entire signaling system)
2. Battery
NOTE:
_
• Before troubleshooting, remove the following • Check the condition of the battery.
part(s): Refer to “CHECKING AND CHARGING
1. seat THE BATTERY” in chapter 3.
2. center cover Minimum open-circuit voltage
3. rear panel 12.8 V or more at 20 °C (68 °F)
4. right side cover
5. headlight assembly • Is the battery OK?
6. front cowling
YES NO
tool(s).
• Refill battery fluid.
Pocket tester terminals.
90890-03112 • Recharge or
replace the battery.
EAS00749
3. Main switch
• Is the main switch OK?
YES NO
Replace the main

switch.
7 - 35
– +
EAS00795 EAS00796
CHECKING THE SIGNALING SYSTEM
4. Wiring 1. The horn fails to sound.
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”. 1. Horn switch
• Is the signaling system’s wiring properly • Check the horn switch for continuity.
connected and without defects? Refer to “CHECKING THE SWITCHES”.
• Is the horn switch OK?
YES NO
YES NO
Check the condition Properly connect or
of each of the signal- repair the signaling The horn switch is
ing system’s circuits. system’s wiring. faulty. Replace the
Refer to “CHECK- left handlebar switch.
ING THE SIGNAL-
ING SYSTEM”. 2. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
Positive tester probe → brown 1
Negative tester probe → ground
Br P

• Push the horn switch.
• Measure the voltage (DC 12 V) of brown at
the horn terminal.
• Is the voltage within specification?
YES NO
The wiring circuit

to the horn connector
is faulty and must be
repaired.
7 - 36
– +
EAS00798
3. Horn 2. The tail/brake light fails to come on.
• Disconnect the pink connector at the horn
1. Tail/brake light bulb and socket
terminal.
• Connect a jumper lead 1 to the horn ter- • Check the tail/brake light bulb and socket
minal and ground the jumper lead. for continuity.
• Set the main switch to “ON”. Refer to “CHECKING THE BULBS AND
• Does the horn sound? BULB SOCKETS”.
• Are the tail/brake light bulb and socket
OK?
Br
YES NO
1
Replace the tail/
brake light bulb,
socket or both.
2. Brake light switches

NO YES • Check the brake light switches for continu-
ity.
The horn is OK. Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
4. Voltage
YES NO
• Connect the pocket tester (DC 20 V) to the
horn connector at the pink terminal as
shown. Replace the brake
Positive tester probe → pink 1 light switch.
Br P

• Measure the voltage (DC 12 V) of pink 1
at the horn terminal.
YES NO
Repair or replace the Replace the horn.

pink lead or ground
lead.
7 - 37
– +
EAS00799
3. Voltage 3. The turn signal light, turn signal indicator
• Connect the pocket tester (DC 20 V) to the light or both fail to blink.
tail/brake light coupler (wire harness side)
1. Turn signal indicator light bulb and socket
as shown.
• Check the turn signal light bulb and socket
Positive tester probe → green/yellow 1
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the turn signal light bulb and socket
1 2 OK?
B L L B
Y G/Y YES NO
Ch Dg Dg Ch
Replace the turn sig-

nal light bulb, socket
or both.
• Pull in the brake levers. 2. Turn signal switch
• Measure the voltage (DC 12 V) of green/
• Check the turn signal switch for continuity.
yellow 1 on the tail/brake light coupler
(wire harness side).
• Is the turn signal switch OK?
YES NO
YES NO
The turn signal

switch is faulty.
Replace the left han-
to the tail/brake light
dlebar switch.
coupler is faulty and
must be repaired.
7 - 38
– +
3. Voltage 4. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness turn signal relay coupler (wire harness
side) as shown. side) as shown.
Positive tester probe → brown 1 Positive tester probe → brown/white 1
Negative tester probe → ground Negative tester probe → ground
Br/W 1 Br/W
1 Br Br
• Set the main switch to “ON”. • Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on brown • Measure the voltage (DC 12 V) on brown/
1 at the turn signal relay coupler (wire white 1 at the turn signal relay coupler
harness side). (wire harness side).
• Is the voltage within specification? • Is the voltage within specification?
YES NO YES NO
The wiring circuit The turn signal relay

from the main switch is faulty and must be
to the turn signal replaced.
relay coupler is faulty
and must be
repaired.
7 - 39
– +
5. Voltage • Set the main switch to “ON”.
• Connect the pocket tester (DC 20 V) to the • Set the turn signal switch to “ ” or “ ”.
turn signal light coupler (wire harness • Measure the voltage (DC 12 V) of the
side) as shown. chocolate 1 or dark green 2 at the turn
signal light coupler (wire harness side) and
È Rear turn signal light chocolate 3 or dark green 4 at the turn
É Front turn signal light signal indicator light coupler (wire harness
Left turn signal light side).
Positive tester probe → chocolate 1 • Is the voltage within specification?
Right turn signal light YES NO
Positive tester probe → dark green 2
Ê Turn signal indicator light from the turn signal
Positive tester probe → chocolate 3 switch to the turn sig-
Negative tester probe → ground nal light coupler is
Positive tester probe → dark green 4 faulty and must be
Negative tester probe → ground repaired.
È
B L L B
Y G/Y
Ch Dg Dg Ch
2 1
É
1
Ch Ch
B B
Dg Dg
B B
4 3
Br Br
Ch Dg Dg Ch
G B B G
7 - 40
– +
EAS00804
4. The fuel level gauge fails to operate. 2. Voltage
1. Fuel sender • Connect the pocket tester (DC 20 V) to the

meter light coupler (wire harness side) as
• Remove the fuel sender from the fuel tank. shown.
• Connect the pocket tester to the fuel
sender coupler (wire harness side) as Positive tester probe → brown 1
shown. Negative tester probe → green 2
Positive tester probe → green 1

E F
2 1
1
B G
Br Br
Dg Ch Ch Dg
B G G B
È 2
É • Measure the voltage (DC 12 V) of brown
1 on the meter light coupler (wire harness
• Measure the fuel sender resistances. side).
Fuel sender resistance (up posi- • Is the voltage within specification?
tion “full” È)
(Ω × 1) YES NO
4 ~ 10 Ω at 20 °C (68 °F)
Fuel sender resistance (down
position “empty” É) Check the wiring
(Ω × 10) connections of the
90 ~ 100 Ω at 20 °C (68 °F) entire signaling sys-
tem.
• Is the fuel sender OK?
YES NO
Replace the fuel

sender.
7 - 41
– +
3. Fuel level gauge
• Move the float up 1 or down 2.
• Check that the fuel level gauge needle
moves to “F” or “E”.
NOTE:
_
Before reading the fuel level gauge, leave the

float in one position (either up or down) for at
least three minutes.
• Does the fuel level gauge needle move

appropriately?
YES NO
Replace the meter

assembly.
4. Wiring
Check the entire signaling system’s wiring.
7 - 42

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ELECTRICAL COMPONENTS........................................................................ 7-1

CHECKING SWITCH CONTINUITY................................................................7-3

CHECKING THE SWITCHES..........................................................................7-5

CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-7

IGNITION SYSTEM ....................................................................................... 7-10

ELECTRIC STARTING SYSTEM .................................................................. 7-15

STARTER MOTOR........................................................................................ 7-20

LIGHTING SYSTEM ......................................................................................7-29

SIGNALING SYSTEM ...................................................................................7-34

“∞” “0” CHECKING SWITCH CONTINUITY

Never insert the tester probes into the cou-

• Before checking for continuity, set the pocket

“ ” indicates a continuity of electricity

The example illustration on the left shows

CHECKING THE SWITCHES

CHECKING THE BULBS AND

Since the headlight bulb gets extremely

• Be sure to hold the socket firmly when

Before checking for continuity, set the pocket

Check each bulb socket for continuity in the

B L/W Y/R Y/R L/W

• Before troubleshooting, remove the following Minimum open-circuit voltage

90890-03112 3. Spark plug

• Is the spark plug in good condition, is it of

4. Ignition spark gap 5. Spark plug cap resistance

Spark plug cap resistance

• Is the spark plug cap OK?

The ignition system

6. Ignition coil resistance 7. Pickup coil resistance

B Y/R W W/R W/L

Replace the ignition

Replace the C.D.I. Properly connect or

B L/W Y/R Y/R L/W

E Rear brake light switch

• The front brake lever is pulled to the handle-

• Before troubleshooting, remove the following THE BATTERY” in chapter 3.

3. Starter motor 4. Starter relay

YES NO Replace the starter

5. Main switch 9. Wiring

Replace the right

7. Front brake light switch

Replace the front

8. Rear brake light switch

Replace the rear

BRUSH LENGTH LIMIT:

DISASSEMBLING THE STARTER MOTOR

Commutator wear limit

The mica of the commutator must be undercut

b. If any resistance is out of specification,

Brush length wear limit

Brush spring force

b a b ASSEMBLING THE STARTER MOTOR

Always use a new O-ring.

Align the match mark a on the starter motor

• starter motor rear cover bolts

• Before troubleshooting, remove the following

Engine tachometer YES NO

3. Charging voltage 4. Charging coil resistance

B Y/R W W/R W/L

NO YES • Check the wiring connections of the entire

Replace the rectifier/ Properly connect or

V High beam indicator light