– +

ELEC
CHAPTER 7.
ELECTRICAL

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

SWITCHES ................................................................................................... 7-3

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

CHECKING THE SWITCHES ....................................................................... 7-4

CHECKING OF BULBS ................................................................................ 7-6

KINDS OF BULBS ................................................................................. 7-6
CHECKING BULB CONDITION ............................................................ 7-6

IGNITION SYSTEM ...................................................................................... 7-8

CIRCUIT DIAGRAM .............................................................................. 7-8
TROUBLESHOOTING .......................................................................... 7-9

ELECTRIC STARTING SYSTEM ............................................................... 7-13

CIRCUIT DIAGRAM ............................................................................ 7-13
STARTING CIRCUIT OPERATION .................................................... 7-14
TROUBLESHOOTING ........................................................................ 7-15
STARTER MOTOR ............................................................................. 7-19

CHARGING SYSTEM ................................................................................. 7-25

CIRCUIT DIAGRAM ............................................................................ 7-25
TROUBLESHOOTING ........................................................................ 7-26

LIGHTING SYSTEM ................................................................................... 7-28

CIRCUIT DIAGRAM ............................................................................ 7-28
TROUBLESHOOTING ........................................................................ 7-29
LIGHTING SYSTEM CHECK .............................................................. 7-31

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

CIRCUIT DIAGRAM ............................................................................ 7-34
TROUBLESHOOTING ........................................................................ 7-36
SIGNAL SYSTEM CHECK .................................................................. 7-38
 – +
ELEC
 – +
ELECTRICAL COMPONENTS ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 Fuel sender
2 Starting circuit cut-off relay
3 Rectifier/regulator
4 Rear brake switch
5 Starter relay
6 Battery
7 Main switch

7-1
 – +
ELECTRICAL COMPONENTS ELEC
1 Ignition coil
2 Flasher relay
3 CDI unit
4 Neutral switch
5 Horn

7-2
 – +
SWITCHES ELEC
EAS0010

SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester.
If the continuity reading is incorrect, check the
wiring connections and if necessary, replace
the switch.

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
the leads.

Pocket tester
90890-03112

NOTE:
● Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.

● When checking for continuity, switch back

and forth between the switch positions a few

times.
The terminal connections for switches (e.g.,
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
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 black/white and
black when the switch is set to “OFF” or
“LOCK”.
There is continuity between brown and red
when the switch is set to “ON”.

7-3
 – +
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 the “CHECKING SWITCH CONTINUITY” section.
Damage/wear → Repair or replace the switch.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.

6 Br R B B/W = 9 8
LOCK Br
L/W B B/W
OFF
OFF OFF G/Y
ON
ON RUN

Br B
B/W R

3 1
P B L/Y
OFF
B/Y
ON

5
Dg Br/W Ch P Br/W Ch
R
L/Y B Br
N
L B/Y Dg L

7
Br L
OFF
PO
ON

2
Br Y
OFF
ON

4
Y G
HI
LO

B A C
10A
Sb

7-4
 – +
CHECKING THE SWITCHES ELEC
1 Clutch switch
2 Pass switch
3 Horn switch
4 Dimmer switch
5 Turn switch
6 Main switch
7 Lights switch
8 Front brake switch
9 Engine stop switch
0 Start switch
A Fuse
B Rear brake switch
C Neutral switch

7-5
 – +
CHECKING OF BULBS ELEC
CHECKING OF BULBS
(FOR HEADLIGHT, TAIL/BLAKE
LIGHT, FLASHER LIGHT, METER
LIGHT, ETC.)

To determine the condition of a bulb check for

continuity at the bulb terminal.

KINDS OF BULBS
The bulbs used in motorcycles can be classi-
fied by shape of socket and use.

A and B are the main types used in head-

lights.

C is mainly used for the flasher light and tail/

brake light.

D and E are mainly used for meter lights and

other indicator lights.

CHECKING BULB CONDITION

1.Remove the bulb.
NOTE:
● Bulbs of the A and B type uses a bulb

holder. Remove the bulb holder before

removing the bulb itself. Most of the bulb
holders for this type can be removed by turn-
ing counterclockwise.
● Most of the bulbs of C and D type can be

removed from the bulb sockets by pushing

and turning them counterclockwise.
● Bulbs of the E type can just be pulled out.

CAUTION:
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead. Oth-
erwise, the lead may be pulled off the termi-
nal in the coupler.

WARNING
Headlight bulbs become very hot even after
a short time. Keep flammable products
away from a hot headlight bulb and be
careful never to touch it, before it had time
to cool down.

7-6
 – +
CHECKING OF BULBS ELEC
2.Check for continuity at the bulb terminals.

*****************************************************
Checking steps:
● Set the pocket tester selector to “Ω × 1”.
● Connect the tester leads to the respective
bulb terminals. Take for example a 3-termi-
nal bulb as shown left. First check the conti-
nuity between the terminals 1 and 2 by
connecting the tester (+) lead to the terminal
1 and the tester (–) lead to the terminal 2.
Then check the continuity between the termi-
nals 1 and 3 by connecting the tester (+)
lead still to the terminal 1 and the tester (–)
lead to the terminal 3. If the tester shows “∞”
in either case, replace the bulb.
*****************************************************

3.Check the bulb socket by installing a proven

bulb to it. As in the checking of bulbs, con-
nect the pocket tester leads to the respective
leads of the socket and check for continuity
in the same manner as mentioned above.

7-7
 1 B/W

LOCK Br B B Br W B W W O O
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W
CIRCUIT DIAGRAM

B B B
IGNITION SYSTEM

Br

10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y

X Y
L/W
B
B
B Z
B B
Br Br
Br/W
Br

7-8
W P P
B
9 9 Br 0 Br/W
B

P Y/R L Br/W L/Y

Y C
Br L Dg Ch
D E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B

(BLUE) (BLUE) (BLACK) (BLACK)

R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
IGNITION SYSTEM

G B Sb Y Y G Ch Dg

Sb L Dg Ch L Y

4 CDI unit
P L L K O J B L L B
L L N M
Sb Y Y
G G
B B

6 Spark plug
ELEC

5 Ignition coil
B B Ch Dg Dg Ch

1 Main switch
B B
Sb

3 CDI magneto
(GREEN) (GREEN)
–

O B B
B B B B

8 Engine stop switch

+
 – +
IGNITION SYSTEM ELEC
TROUBLESHOOTING

IF IGNITION SYSTEM SHOULD BECOME INOPERATIVE

(NO SPARK OR INTERMITTENT SPARK)

Procedure
Check;
1.Spark plug 6.Engine stop switch
2.Ignition spark gap 7.Source coil resistance
3.Spark plug cap resistance 8.Pickup coil resistance
4.Ignition coil resistance 9.Wiring connection (ignition system)
5.Main switch
NOTE:
● Remove the following parts before troubleshooting.

1)Headlight unit
2)Seat
3)Fuel tank
● Use the following special tools in this troubleshooting.

Pocket tester: Ignition checker:

90890-03112 90890-06754

1.Spark plug
● Check the spark plug type, condition and
gap.
Refer to the “SPARK PLUG INSPECTION”
section in CHAPTER 3.
Standard spark plug:
D8EA (NGK) or X24ES-U (DENSO)
Spark plug gap:
0.6 ~ 0.7 mm INCORRECT

CORRECT

Repair or replace spark plug.

*

7-9
 – +
IGNITION SYSTEM ELEC

* C0NTINUITY

2.Ignition spark gap

● Disconnect the spark plug cap from the
spark plug.
● Connect the ignition checker 1 between
cylinder head and spark plug cap 2, and
set the specified spark gap 3.

● Turn the main switch to “ON”, then apply

clutch lever or shift the transmission into
neutral. SPARK
● Push the start switch or kick the kick crank.
● Check the ignition spark condition.
Minimum spark gap:
6 mm Ignition circuit is good.

OUT OF
SPECIFICATION

3.Spark plug cap resistance

● Remove the spark plug cap.
● Connect the pocket tester (Ω × 1k) to the
spark plug cap.

● Checking the spark plug cap for the speci- OUT OF SPECIFICATION
fied resistance.
Spark plug cap resistance:
10 kΩ at 20°C Replace spark plug cap.
MEETS
SPECIFICATION

*
7 - 10
 – +
IGNITION SYSTEM ELEC

* C0NTINUITY

4.Ignition coil resistance

● Disconnect the ignition coil lead (Orange)
from the wire harness.
● Connect the pocket tester to the ignition
coil.
Primary coil: (Ω × 1)
Tester (+) lead → Orange 1 terminal
Tester (–) lead → Ignition coil base 2
Secondary coil: (Ω × 1k)
Tester (+) lead → Spark plug lead 3
Tester (–) lead → Ignition coil base 2

● Measure the primary and secondary coil

resistances. OUT OF SPECIFICATIONS
Primary coil resistance È:
0.32 ~ 0.48 Ω at 20°C
Secondary coil resistance É:
5.68 ~ 8.52 kΩ at 20°C Replace ignition coil.

BOTH MEETS
SPECIFICATIONS

5.Main switch INCORRECT

● Check the main switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace main switch.
CORRECT

INCORRECT
6.Engine stop switch
● Check the engine stop switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section. Replace handlebar switch (right).

CORRECT

7 - 11
 – +
IGNITION SYSTEM ELEC

* C0NTINUITY

7.Source coil resistance

● Disconnect the CDI magneto coupler from
the wire harness.
● Connect the pocket tester (Ω × 100) to the
source coil.
Tester (+) lead → Brown 1 terminal
Tester (–) lead → Green 2 terminal

3 CDI magneto OUT OF SPECIFICATION

● Measure the source coil resistance.
Source coil resistance:
688 ~ 1,032 Ω at 20°C
Replace source coil.
MEETS
SPECIFICATION

8.Pickup coil resistance

● Disconnect the CDI magneto coupler from
the wire harness.
● Connect the pocket tester (Ω × 100) to the
pickup coil.
Tester (+) lead → Red 1 terminal
Tester (–) lead → White 2 terminal

OUT OF SPECIFICATION
3 CDI magneto
● Measure the pickup coil resistance.
Pickup coil resistance:
248 ~ 372 Ω at 20°C Replace pickup coil.
MEETS
SPECIFICATION

9.Wiring connection POOR CONNECTION

● Check the entire ignitions system for con-

nections.
Refer to the “WIRING DIAGRAM” section. Correct.

CORRECT

CDI unit is faulty. Replace it.

7 - 12
 1 B/W

LOCK Br B B Br W B W W O O
OFF

Y Fuse
R R R Y/R R R
W W
ON Br Br 4 B

X Battery
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W

7 Start switch
1 Main switch

Z Starter relay
O Br B/W G
2

W Starter motor
I Clutch switch
Y/R Y/R
3 B R W

O Neutral switch
CIRCUIT DIAGRAM

B B B 8 Engine stop switch

Br

10A
Br
L/W B/W
Br

[ Starting circuit cut-off relay

R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y

Y
ELECTRIC STARTING SYSTEM

X L/W
B
B
B Z
B B
Br Br
Br/W
W Br

7 - 13
9 P 9 P
B Br 0 Br/W
B

P Y/R L Br/W L/Y

Y C
Br L Dg Ch
D E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B

(BLUE) (BLUE) (BLACK) (BLACK)

R S T U VW
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
ELECTRIC STARTING SYSTEM

G B Sb Y Y G Ch Dg

Sb L Dg Ch L Y

P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC

B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–

O B B
B B B B
+
 – +
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT OPERATION
The starting circuit on this model consist of the
starter motor, starter relay, and the relay unit
(starting circuit cut-off relay). If the engine stop
switch and the main switch are both closed,
the starter motor can operate only if:

The transmission is in neutral (the neutral

switch is closed).

or if

The clutch lever is pulled to the handlebar

(the clutch switch is closed).

The starting circuit cut-off relay prevents the

starter from operating when neither of these
conditions has been met. In this instance, the
starting circuit cut-off relay is open so current
cannot reach the starter motor.

When one of both of the above conditions

have been met, however, the starting circuit
cut-off relay is closed, and the engine can be
started by pressing the starter switch.

WHEN THE TRANSMISSION IS

IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED IN

1 Battery
2 Starter relay
3 Starter motor
4 Main switch
5 Starting circuit cut-off relay (relay assembly)
6 Clutch switch
7 Neutral switch
8 Start switch
9 Engine stop switch

7 - 14
 – +
ELECTRIC STARTING SYSTEM ELEC
TROUBLESHOOTING

STARTER MOTOR DOES NOT OPERATE.

Procedure
Check;
1.Fuse 6.Main switch
2.Battery 7.Engine stop switch
3.Starter motor 8.Neutral switch
4.Starter relay 9.Clutch switch
5.Starting circuit cut-off relay (relay assembly) 10.Start switch
11.Wiring connection (electric starting system)
NOTE:
● Remove the following parts before troubleshooting.

1)Side cover (right)

2)Headlight unit
3)Seat
4)Fuel tank
● Use the following special tool in this troubleshooting.

Pocket tester:
90890-03112

1.Fuse
INCORRECT
● Connect the pocket tester “Ω × 1” to the
fuse.
● Check the fuse for continuity.

CONTINUITY Replace fuse.

2.Battery
● Check the battery condition. INCORRECT
● Check the battery fluid level, battery termi-
nals and specific gravity.
Specific gravity:
● Refill battery fluid.
1.280 at 20°C
● Clean battery terminals.
● Recharge or replace battery.
CORRECT

7 - 15
 – +
ELECTRIC STARTING SYSTEM ELEC

* C0NTINUITY

3.Starter motor *
● Connect the battery positive terminal 1 WARNING
and starter motor cable 2 using the jumper ● A wire for the jumper lead must have the
lead 3 . equivalent capacity as that of the battery
●
*
Check the starter motor operation. lead or more, otherwise it may cause the
jumper lead to be burned.
● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.

INOPERATIVE

Repair or replace starter motor.

C0NTINUITY

4.Starter relay
Disconnect the starter relay coupler from
*
● WARNING
the wire harness. ● A wire for the jumper lead must have the
● Connect the battery (12 V) to the starter equivalent capacity as that of the battery
relay terminals, using the jumper leads .
Battery (+) lead → Yellow/Red 1 terminal
* lead or more, otherwise it may cause the
jumper lead to be burned.
Battery (–) lead → Black 2 terminal ● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
the vicinity.

DOES NOT MOVES

● Check the starter motor for operation. Replace starter relay.

MOVES

7 - 16
 – +
ELECTRIC STARTING SYSTEM ELEC

* C0NTINUITY

5.Starting circuit cut-off relay

● Disconnect the relay lead coupler from the
wire harness.
● Connect the pocket tester (Ω × 1) and bat-
tery (12 V) to relay.
Step 1:
Battery (+) lead → Brown terminal 1
Battery (–) lead → Sky blue terminal 2
Tester (+) lead → Brown terminal 1
Tester (–) lead → Red/White terminal 4
Step 2:
Battery (+) lead → Brown terminal 1
Battery (–) lead →
Blue/Yellow terminal 3
Tester (+) lead → Brown terminal 1
Tester (–) lead → Red/White terminal 4

NO CONTINUITY

● Check the relay for continuity. Replace relay.

CONTINUITY

6.Main switch INCORRECT

● Check the main switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace main switch.

CORRECT

7.Engine stop switch INCORRECT

● Check the engine stop switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace handlebar switch (right).

CORRECT

*
7 - 17
 – +
ELECTRIC STARTING SYSTEM ELEC

* C0NTINUITY

8.Neutral switch INCORRECT

● Check the neutral switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace neutral switch.

CORRECT

9.Clutch switch INCORRECT

● Check the clutch switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Replace clutch switch.

CORRECT

10.Start switch
INCORRECT
● Check the start switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section.
Replace handlebar switch (right).
CORRECT

11.Wiring connection POOR CONNECTION

● Check the entire ignition system for conti-
nections.
Refer to the “WIRING DIAGRAM” section.
Correct.

7 - 18
 – +
ELECTRIC STARTING SYSTEM ELEC
STARTER MOTOR
1 Brush
2 Armature
3 O-ring
4 O-ring

BRUSH LENGTH LIMIT:

A
3.5 mm
COMMUTATOR WEAR LIMIT:
B
21 mm
MICA UNDER CUT:
C
1.5 mm
ARMATURE COIL RESISTANCE:
D
0 Ω at 20°C

7 - 19
 – +
ELECTRIC STARTING SYSTEM ELEC
Removal
1.Remove:
● Carburetor

Refer to the “CARBURETOR” section in

CHAPTER 5.
2.Remove:
● Clutch cable

Refer to the “WIRE, CABLE AND TUBE”

section in CHAPTER 4.

3.Disconnect:
● Starter motor lead 1

4.Remove:
● Starter motor 2

5.Remove:
● Bolts (starter motor front cover)

6.Remove:
● Starter motor yoke 1

● O-ring 2

7.Remove:
● Armature 1

Inspection and repair

1.Inspect:
● Commutator

Dirty → Clean it with #600 grit sandpaper.

2.Measure:
● Commutator diameter a

Out of specification → Replace starter motor.

Commutator wear limit:

21 mm

7 - 20
 – +
ELECTRIC STARTING SYSTEM ELEC
3.Measure:
● Mica undercut b

Out of specification → Scrape the mica to

proper value use a hacksaw blade can be
ground to fit.

Mica undercut:
1.5 mm

NOTE:
the mica insulation of the commutator must be
undercut to ensure proper operation of com-
mutator.

4.Inspect:
● Armature coil (continuity/insulation)

Defects (s) → Replace starter motor.

*****************************************************
Inspecting steps:
● Connect the pocket tester for continuity
check 1 and insulation check 2.

Pocket tester:
90890-03112

● Measure the armature coil resistances.

Armature coil resistance:

Continuity check 1: (Ω × 1)
0 Ω at 20°C
Insulation check 2: (Ω × 1k)
More than 1 MΩ at 20°C

● If the resistance is incorrect, replace the

starter motor.
*****************************************************
5.Measure:
● Brush length a

Out of specification → Replace.

Brush length limit:

3.5 mm

7 - 21
 – +
ELECTRIC STARTING SYSTEM ELEC
6.Measure:
● Brush spring pressure

Fatigue/out of specification → Replace as a

set.

Brush spring pressure:

560 ~ 840 g

7.Inspect
● Bearing

● Oil seal

● O-ring

Wear/damage → Replace.

Assembly
Reverse the “Removal” procedure.
Note the following points.

1.Install:
● Brush

● Brush spring

Using a thin screw driver.

7 - 22
 – +
ELECTRIC STARTING SYSTEM ELEC
2.Install
● Armature 1

3.Install:
● O-ring 1

● Starter motor yoke 2

4.Install
● Starter motor assembly

NOTE:
Align the groove a on the starter motor
assembly with the groove b on the housing.

5.Install:
● O-ring 1 New
● Screw

WARNING
Always use a new O-ring.
6.Install:
● O-ring 2

WARNING
Always use a new O-ring.

NOTE:
Apply a lightly grease to the O-ring 2.

7 - 23
 – +
ELECTRIC STARTING SYSTEM ELEC
Installation
1.Install:
● Starter motor 1

● Starter motor lead 2

Bolt (starter motor):

10 Nm (1.0 m • kg)

T.
R.

7 - 24
 1 B/W

LOCK Br B B Br W B W W O O
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
CIRCUIT DIAGRAM

Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W

B B B
CHARGING SYSTEM

Br

10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y

X Y
L/W
B
B
B Z

7 - 25
B B
Br Br
Br/W
W Br
9 P 9 P
B Br Br/W
B
0

P Y/R L Br/W L/Y

Y CD
Br L Dg Ch
E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B

(BLUE) (BLUE) (BLACK) (BLACK)

CHARGING SYSTEM

R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G

Y Fuse
G B Sb Y Y G Ch Dg

X Battery
Sb L Dg Ch L Y
ELEC

3 CDI magneto
P L L K O J B L L B
–

L L N M
Sb Y Y
G G
B B
B B Ch Dg Dg Ch
B B

2 Rectifier/regulator
Sb
+

(GREEN) (GREEN)
O B B
B B B B
 – +
CHARGING SYSTEM ELEC
TROUBLESHOOTING

THE BATTERY IS NOT CHARGED.

Procedure
Check;
1.Fuse 4.Charging coil resistance
2.Battery 5.Wiring connection (charging system)
3.Charging voltage
NOTE:
● Remove the following parts before troubleshooting.

1)Side cover (right)

2)Seat
3)Fuel tank
● Use the following special tools in this troubleshooting.

Pocket tester: Inductive tachometer:

90890-03112 90890-03113

1.Fuse
NO CONTINUITY
● Connect the pocket tester (Ω × 1) to the
fuse.
● Check the fuse for continuity.

CORRECT Replace fuse.

2.Battery
● Check the battery condition. INCORRECT
● Check the battery fluid level, battery termi-
nals and specific gravity.
Refer to the “BATTERY INSPECTION”
section in CHAPTER 3. ● Refill battery fluid.
Specific gravity: ● Clean battery terminals.
1.280 at 20°C ● Recharge or replace battery.

CORRECT

7 - 26
 – +
CHARGING SYSTEM ELEC

* C0NTINUITY

3.Charging voltage
● Connect the Indicative tachometer to the
spark plug lead.
● Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead → Battery (+) terminal 1
Tester (–) lead → Battery (–) terminal 2

● Start the engine. MEETS SPECIFICATION

● Measure the charging voltage.
Charging voltage:
12 V or more at 3,000 r/min
14.5 V or less at 8,000 r/min Replace battery.

OUT OF
SPECIFICATION

4.Charging coil resistance

● Disconnect the CDI magneto coupler from
the wire harness.
● Connect the pocket tester (Ω × 1) to the
stator coil.
Battery (+) lead → White 1 terminal
Battery (–) lead → Black 2 terminal

OUT OF SPECIFICATION
● Measure the charging coil resistance.
Charging coil resistance:
0.32 ~ 0.48 Ω at 20°C
(White - Black) Replace stator assembly.

MEETS
SPECIFICATION
POOR CONNECTION
5.Wiring connection
● Check the entire charging system for con-
nections.
Refer to the “WIRING DIAGRAM” section. Correct.

CORRECT

Replace rectifier/regulator.

7 - 27
 1 B/W

LOCK Br B B Br W B W W O O
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6

M Headlight
5

S Meter light
Br R B B/W R W W

F Pass switch
O Br B/W G

E Lights switch
2

N Auxiliary light
Y/R Y/R
3 B R W
3 CDI magneto

J Tail/black light
G Dimmer switch
CIRCUIT DIAGRAM

B B B

Br
LIGHTING SYSTEM

T High beam indicator light

10A
Br
L/W B/W
Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y

X Y
L/W
B
B
B Z
B B
Br Br
Br/W
W Br

7 - 28
9 P 9 P
B Br 0 Br/W
B

P Y/R L Br/W L/Y

Y CD
Br L Dg Ch
E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B

(BLUE) (BLUE) (BLACK) (BLACK)

R S T U V W
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
LIGHTING SYSTEM

G B Sb Y Y G Ch Dg

Sb L Dg Ch L Y

P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC

B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–

O B B
B B B B
+
 – +
LIGHTING SYSTEM ELEC
TROUBLESHOOTING

HEADLIGHT, HIGH BEAM INDICATOR LIGHT, TAILLIGHT AND/OR METER LIGHT DO NOT
COME ON.

Procedure
Check;
1.Lighting coil resistance 4.Pass switch
2.Lights switch 5.Wiring connection (entire lighting system)
3.Dimmer switch
NOTE:
● Remove the following parts before troubleshooting.

1)Side cover (right)

2)Headlight unit
3)Seat
● Use the following special tool (s) in this troubleshooting.

Pocket tester:
90890-03112

1.Lighting coil resistance

● Disconnect the CDI magneto coupler from
the wire harness.
● Connect the pocket tester (Ω × 1) to the
stator coil.
Tester (+) lead → Yellow 1 terminal
Tester (–) lead → Black 2 terminal

● Measure the lighting coil resistance. OUT OF SPECIFICATION

Lighting coil resistance.

0.24 ~ 0.36 Ω at 20°C
(Yellow - Black)
Replace stator assembly.
MEETS
SPECIFICATION

2.Lights switch INCORRECT

● Check the lights switch for continuity.

Refer to the “CHECKING THE
SWITCHES” section. Lights switch is faulty, replace handlebar
switch (right).
CORRECT

*
7 - 29
 – +
LIGHTING SYSTEM ELEC

* C0NTINUITY

INCORRECT
3.Dimmer switch
● Check the dimmer switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section. Dimmer switch is faulty, replace handlebar
switch (left).
CORRECT

INCORRECT
4.Pass switch
● Check the pass switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section. Pass switch is faulty, replace handlebar
switch (left).
CORRECT

5.Wiring connection POOR CONNECTION

● Check the entire lighting system for con-

nections.
Refer to the “WIRING DIAGRAM” section. Correct.

CORRECT

Check condition of each circuit for lighting

system.
Refer to the “LIGHTING SYSTEM CHECK”
section.

7 - 30
 – +
LIGHTING SYSTEM ELEC
LIGHTING SYSTEM CHECK
1.Headlight and high beam indicator light do not come on.

1.Bulb and bulb socket NO CONTINUITY

● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING OF BULBS” sec-
tion. Bulb and/or bulb socket are faulty, replace.

CONTINUITY

2.Voltage Headlight
● Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light
leads.
Headlight:
Tester (+) lead →
Yellow 2 or Green 1 lead
Tester (–) lead → Black 3 lead
High beam indicator light:
Tester (+) lead → Yellow 4 lead High beam indicator light
Tester (–) lead → Black 5 terminal
È When dimmer switch is “LO” position.
É When dimmer switch is “HI” position.
● Start the engine.
● Turn the lights switch to “ON”.
● Turn the dimmer switch to “LO” or “HI” posi-
tion.
● Check for voltage (12 V) on the “Green”
OUT OF SPECIFICATION
and “Yellow” lead at bulb socket connector.
MEETS SPECIFI-
CATION (12 V)
Wiring circuit from main switch to bulb socket
This circuit is good. connector is faulty, repair.

7 - 31
 – +
LIGHTING SYSTEM ELEC
2.Meter light does not come on.

1.Bulb and bulb socket

● Check the bulb and bulb socket for continu- NO CONTINUITY
ity.
Refer to the “CHECKING OF BULBS” sec-
tion.
Bulb and/or bulb socket are faulty, replace.
CONTINUITY

2.Voltage
● Connect the pocket tester (DC 20 V) to the
bulb socket leads.
Tester (+) lead → Blue 1 terminal
Tester (–) lead → Black 2 terminal

OUT OF SPECIFICATION

● Start the engine.

● Turn the lights switch to “ON” or “PO”.
● Check for voltage (12 V) on the “Blue” lead Wiring circuit from main switch to bulb socket
at the bulb socket connector. connector is faulty, repair.

MEETS SPECIFI-
CATION (12 V)

This circuit is good.

7 - 32
 – +
LIGHTING SYSTEM ELEC
3.Taillight does not come on

1.Bulb and bulb socket

NO CONTINUITY
● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING THE
SWITCHES” section.
Bulb and/or bulb socket are faulty, replace.
CONTINUITY

2.Voltage
● Connect the pocket tester (DC 20 V) to the
bulb socket leads.
Tester (+) lead → Blue 1 terminal
Tester (–) lead → Black 2 terminal

OUT OF SPECIFICATION

● Start the engine.

● Turn the lights switch to “ON” or “PO”.
● Check for voltage (12 V) on the “Blue” lead Wiring circuit from main switch to bulb socket
at the bulb socket connector. connector is faulty, repair.

MEETS SPECIFI-
CATION (12 V)

This circuit is good.

7 - 33
 1 B/W

LOCK Br B B Br W B W W O O
OFF R R R Y/R R R
W W
ON Br Br 4 B
(GREEN) Y/R Y
B/W B/W
G G
B B 6
5
Br R B B/W R W W
O Br B/W G
2 Y/R Y/R
3 B R W
CIRCUIT DIAGRAM

B B B

Br

10A
Br
L/W B/W
SIGNALING SYSTEM

Br
R [ L/Y R/W A B
Y Sb Br
7 8 Br B
R R
G/Y B
R OFF OFF
R
Y/R R/W ON RUN (BLACK) (BLACK)
B L/W
R/W Sb L/Y
R
R/W G/Y

X Y
L/W
B
B
B Z
B B
Br Br
Br/W
W Br

7 - 34
9 P 9 P
B Br 0 Br/W
B

P Y/R L Br/W L/Y

Y CD
Br L Dg Ch
E F G H I
OFF OFF OFF HI R P Br/W Ch Ch Br/W P
L/Y L/Y
Q Dg Dg ON PO ON LO N L/Y B Br Y/R B L/Y
B/Y B/Y
Ch Ch ON L B/Y Dg L L Dg B

(BLUE) (BLUE) (BLACK) (BLACK)

R S T U VW
Sb G G Sb
B Dg Ch B
B B
Br L L Br Y G
SIGNALING SYSTEM

G B Sb Y Y G Ch Dg

Sb L Dg Ch L Y

P L L K O J B L L B
L L N M
Sb Y Y
G G
B B
ELEC

B B Ch Dg Dg Ch
B B
Sb
(GREEN) (GREEN)
–

O B B
B B B B
+
 – +
SIGNALING SYSTEM ELEC
1 Main switch
9 Horn
0 Flasher relay
A Front brake switch
B Rear brake switch
D Horn switch
H Turn signal switch
J Tail/black light
K Rear turn signal light
L Front turn signal light
O Neutral switch
P Fuel sender
R Fuel gauge
U Neutral indicator light
V Turn indicator light
X Battery
Y Fuse

7 - 35
 – +
SIGNALING SYSTEM ELEC
TROUBLESHOOTING

● FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT DO NOT COME ON.
● HORN DOES NOT SOUND.
● FUEL GAUGE DOES NOT OPERATED.

Procedure
Check;
1.Fuse
2.Battery
3.Main switch
4.Wiring connection (entire signal system)
NOTE:
● Remove the following parts before troubleshooting.

1)Side cover (right)

2)Headlight unit
3)Seat
4)Fuel tank
● Use the following special tool (s) in this troubleshooting

Pocket tester:
90890-03112

1.Fuse
● Remove the fuse.
● Connect the pocket tester (Ω × 1) to the NO CONTINUITY
fuse.
● Check the fuse for continuity.
Refer to the “FUSE INSPECTION” section
in CHAPTER 3. Fuse is faulty, replace it.

CONTINUITY

2.Battery INCORRECT

● Check the battery condition.

Refer to the “BATTERY INSPECTION”
section in CHAPTER 3. ● Refill battery fluid.
Specific gravity: ● Clean battery terminals.
1.280 at 20°C ● Recharge or replace battery.

CORRECT

*
7 - 36
 – +
SIGNALING SYSTEM ELEC

* C0NTINUITY

INCORRECT
3.Main switch
● Check the main switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section. Main switch is faulty, replace it.

CORRECT

4.Wiring connection
POOR CONNECTION
● Check the entire signal system for connec-
tions.
Refer to the “WIRING DIAGRAM” section.
Correct.
CORRECT

Check condition of each circuit for signal sys-

tem.
Refer to the “SIGNAL SYSTEM CHECK”
section.

7 - 37
 – +
SIGNALING SYSTEM ELEC
SIGNAL SYSTEM CHECK
1.Horn does not sound.

1.Horn switch INCORRECT

● Check the horn switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section.
Horn switch is faulty, replace handlebar
CORRECT switch (left).

2.Voltage
● Connect the pocket tester (DC 20 V) to the
horn lead.
Tester (+) lead → Brown 1 lead
Tester (–) lead → Frame ground

OUT OF SPECIFICATION

● Turn the main switch to “ON”.

● Check for voltage (12 V) on the “Brown” Wiring circuit from main switch to horn termi-
lead at the horn terminal. nal is faulty, repair.

MEETS SPECIFI-
CATION (12 V)

7 - 38
 – +
SIGNALING SYSTEM ELEC

* C0NTINUITY

3.Horn
● Disconnect the “Pink” lead at the horn ter-
minal.
● Connect a jumper lead 1 to the horn termi-
nal and ground the jumper lead.
● Turn the main switch to “ON”.

HORN IS SOUNDED

Horn is good.

HORN IS NOT
SOUNDED

4.Voltage
● Connect the pocket tester (DC 20 V) to the
horn at the Pink terminal.
Tester (+) lead → Pink 1 lead
Tester (–) lead → Frame ground

OUT OF SPECIFICATION

● Turn the main switch to “ON”.

● Check for voltage (12 V) on the “Pink” lead
at the horn terminal. Horn is faulty, replace it.

MEETS SPECIFI-
CATION (12 V)

Adjust or replace horn.

7 - 39
 – +
SIGNALING SYSTEM ELEC
2.Brake light does not come on.

1.Bulb and bulb socket

NO CONTINUITY
● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING OF BULBS” sec-
tion. Bulb and/or bulb socket are faulty, replace.
CONTINUITY

2.Brake switch
INCORRECT
● Check the brake switches for continuity.
Refer to the “CHECKING THE
SWITCHES” section.

CORRECT Brake switch is faulty, replace it.

3.Voltage
● Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead → Yellow 1 terminal
Tester (–) lead → Black 2 terminal

OUT OF SPECIFICATION
● Turn the main switch to “ON”.
● The brake level is pulled in or brake pedal
is stopped down.
● Check for voltage (12 V) on the “Yellow” Wiring circuit from main switch to bulb socket
lead at the bulb socket connector. connector is faulty, repair.

MEETS SPECIFI-
CATION (12 V)

This circuit is good.

7 - 40
 – +
SIGNALING SYSTEM ELEC
3.Flasher light and/or turn indicator light do not blink.

1.Bulb and bulb socket

NO CONTINUITY
● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING OF BULBS” sec-
tion. Bulb and/or bulb socket are faulty, replace.

CONTINUITY

2.Turn signal switch INCORRECT

● Check the turn signal switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section.
Turn signal switch is faulty, replace handle-
CORRECT bar switch (left).

3.Voltage
● Connect the pocket tester (DC 20 V) to the
flasher relay.
Tester (+) lead → Brown 1 terminal
Tester (–) lead → Frame ground
● Turn the main switch to “ON”.
● Check for voltage (12 V) on the “Brown”
OUT OF SPECIFICATION
lead at the flasher relay terminal.
MEETS SPECIFI-
CATION (12 V)
Wiring circuit from main switch to flasher
* relay connector is faulty, repair.

7 - 41
 – +
SIGNALING SYSTEM ELEC

* C0NTINUITY

4.Voltage
● Connect the pocket tester (DC 20 V) to the
flasher relay.
Tester (+) lead → Brown/White 1 terminal
Tester (–) lead → Frame ground

OUT OF SPECIFICATION

● Turn the main switch to “ON”.

● Check for voltage (12 V) on the “Brown/
White” lead at the flasher relay terminal. Flasher relay is faulty, replace it.

MEETS SPECIFI-
CATION (12 V)

5.Voltage
● Connect the pocket tester (DC 20 V) to the
bulb socket connector.
At flasher light (left):
Tester (+) lead → Chocolate 1 lead
Tester (–) lead → Frame ground
At flasher light (right):
Tester (+) lead → Dark green 2 lead
Tester (–) lead → Frame ground
● Turn the main switch to “ON”.
OUT OF SPECIFICATION
● Turn the turn signal switch to “L” or “R”.
● Check for voltage (12 V) on the “Chocolate”
lead or “Dark green” lead at the bulb socket
connector.
Wiring circuit from turn signal switch to bulb
MEETS SPECIFI- socket connector is faulty, repair.
CATION (12 V)

This circuit is good.

7 - 42
 – +
SIGNALING SYSTEM ELEC
4.Natural indicator light does not come on.
NO CONTINUITY
1.Bulb and bulb socket
● Check the bulb and bulb socket for continu-
ity.
Refer to the “CHECKING OF BULBS” sec- Bulb and/or bulb socket are faulty, replace.
tion.

CONTINUITY

INCORRECT
2.Neutral switch
● Check the neutral switch for continuity.
Refer to the “CHECKING THE
SWITCHES” section. Neutral switch is faulty, replace it.

CORRECT

3.Voltage
● Connect the pocket tester (DC 20 V) to the
bulb socket connector.
Tester (+) lead → Brown 1 terminal
Tester (–) lead → Frame ground

OUT OF SPECIFICATION

● Turn the main switch to “ON”.

● Check for voltage (12 V) on the “Brown” Wiring circuit from main switch to bulb socket
lead at bulb socket connector. connector is faulty, repair.

MEETS SPECIFI-
CATION (12 V)

This circuit is good.

7 - 43
 – +
SIGNALING SYSTEM ELEC
5.Fuel meter does not operate.

1.Fuel sender
● Remove the fuel sender 1 from the fuel
tank.
● Connect the pocket tester to the fuel
sender coupler.
Tester (+) lead → Green 2 terminal
Tester (–) lead → Black 3 terminal

● Check the fuel sender for the specified

resistance.
Fuel sender resistance (Up 4): OUT OF SPECIFICATION
(Ω × 1)
4 ~ 10 Ω at 20°C
Fuel sender resistance (Down 5):
(Ω × 10)
90 ~ 100 Ω at 20°C Replace fuel sender.

BOTH MEET
SPECIFICATION

2.Voltage
● Connect the pocket tester (DC 20 V) to the
fuel meter coupler.
Tester (+) lead → Brown 1 terminal
Tester (–) lead → Black 2 terminal

● Turn the main switch to “ON”. OUT OF SPECIFICATION

● Check for voltage (12 V) on the “Brown”
lead at the fuel meter coupler.

MEETS SPECIFI- Check the entire signal system for connec-

CATION (12 V) tions.

7 - 44
 – +
SIGNALING SYSTEM ELEC

* C0NTINUITY

3.Fuel meter
● Move the float to “UP 1” or “DOWN 2”.

NOTE:
Before reading the meter, stay put the float for
more than three minutes respectively at “UP”
or “DOWN”.

DOES NOT MOVE

● Turn the main switch to “ON”.

● Check the fuel meter needle moves “FULL”
or “EMPTY”. Replace fuel meter.

MOVES

4.Wiring connection
● Check the entire signal system for connec-
tion.
Refer to the “WIRING DIAGRAM” section.

7 - 45