1 Chapter 7 Electrical System Table of Contents 1 7 Battery ............................................................................ 7-2 Do’s And Don'ts .............................................................. 7-4 Electrical Checking System ............................................ 7-8 Standard Operating Procedure ....................................... 7-19 Battery Charging And Low Battery Indication Circuit ...... 7-36 Ignition Circuit ................................................................ 7-37 Horn Circuit .................................................................... 7-38 Brake Lamp Circuit ......................................................... 7-39 Fuel Pump Circuit ........................................................... 7-40 Starter Motor Circuit ....................................................... 7-41 Side Stand Circuit ........................................................... 7-42 Radiator Fan Motor Circuit .............................................. 7-43 Side Indicator Circuit ....................................................... 7-44 Fuel Meter Circuit ............................................................ 7-45 Fuel Injector Circuit ......................................................... 7-46 EVAP Purge Valve Circuit ............................................... 7-47 MIL Indication Circuit ...................................................... 7-48 Low Oil Pressure Indication Circuit ................................. 7-49 Engine RPM Indication Circuit ........................................ 7-50 ABS Circuit ..................................................................... 7-51 Lighting Circuit ................................................................ 7-52 Gear Indication Circuit .................................................... 7-53 USB Circuit ..................................................................... 7-54
7-2 ELECTRICAL SYSTEM Battery • Make Exide • Terminal Voltage 12 Volt • Type VRLA Battery • Capacity 8 Ah • ChargingCurrentSpecification 4.0 Amp • ChargingVoltageSpecification 14.5 + 0.1 V • Battery Charger Metafab or AppleEnergy Make VRLA Battery Initial Filling Seal Plug cap strip Fillerport seal Step 2 : Get the electrolyte ready • Remove electrolyte container from the packing. Battery Technical Specification Step 1 : Get the battery ready • Place the battery on a flat leveled and preferably on a insulated surface. • Remove the filler port seal of the battery. • Remove the sealing cap plug strip. • Keep the sealing cap plug aside as this is to be used as battery sealing plug strip later.
7-3 ELECTRICAL SYSTEM Battery Step 4 : Check the electrolyteflow Make sure that air bubbles are visible in the electrolyte and which is seen in all the 6 tubes of the container. Leave the container on the battery as it is for 30 minutes. Step 5 : Take away the bottles Be sure that the entire electrolyte has flown down inside the battery. Tap the bottom of the container and gently remove the empty container. Step 6 : Attach the sealing cap Fit the sealing cap plug strip tightly on the filler ports of the battery. Ensure by pressing firmly that the cap has become flush with the top surface of battery. Step 7 : Charge the battery Charge the battery on BAL recommended VRLA battery charger as per standard SOP. A B Step 3 : Fill the battery A. Hold the electrolyte container upside down. Ensure the container is upright and not tilled. If tilled the electrolyte might fail to flow. Now force the container down until seals get pierced. Note Never use conducting materials like screwdrivers which produce the spark near battery terminal. Do not add any additional electrolyte. Note B. Place the container upright on battery. Match the 6 seals with the respective filler ports.
7-4 ELECTRICAL SYSTEM Do’s and Dont’s Do's Dont's • Do not apply grease to poles / terminals. • Apply petroleum jelly to battery terminals. 3 • Always charge the battery with the help of recommended VRLA battery charger. • Do not use any other battery charger for charging VRLA battery. • Check open circuit voltage by multimeter • Do not short circuits the poles to check battery condition. • Always use battery tester for checking condition of VRLA battery. • Do not fit extra electrical accessories. This will result in wiring getting short and battery would get discharged. This will shorten life of battery. • Use proper tools. (10 mm T spanner or Philips screw driver). • Do not hammer battery terminals.
7-5 ELECTRICAL SYSTEM Do’s and Dont’s Do's Dont’s Ensure that horn is firmly fitted on fairing structure central. Do not apply pressurised water jet directly on horn resonator. Ensure that horn is free from dust and mud accumulation. Never adjust nut on horn cap side and bracket end (back side) as it will result in horn malfunctioning and failure. Ensure that horn wires are intact. Do not remove silicon sealant from adjustment screw as it will result in water entry into horn. Ensure that horn switch button in good condition. Ensure that battery is fully charged. Do not hit by mallet / screw driver on horn resonator. Adjust horn by phillips screw driver - without removing silicon sealant from adjustment screw. - by rotating the screw in direction of arrow provided in the screw. Ensure that resonator is not pressed by any portion of cables or wiring harness as it will result in distorted sound.
7-6 ELECTRICAL SYSTEM Do’s and Dont’s Ignition System Do's • Always install recommended capacity of battery on the bike. • Always replace spark plug by correct heat range plug. • Check and adjust spark plug gap periodically. Adjust it to 0.7 ~ 0.9 mm by wire gauge. • Replace spark plug at every 40,000 kms. • Check for firm fitment of spark plug in cylinder head - Tightening torque : 1.3 ~ 1.5 Kgf-m. • Ensure H.T. cable secondary connection is firmly fitted in spark plug cap and H.T. coil. • Ensure that magneto coupler is firmly fitted. • Always use a right size socket during removal and re-installation of spark plug. • During periodic service make use of spark plug cleaning machine to clean spark plug electrodes and check proper functioning of all spark plugs. Dont’s • Do not replace spark plug by non recommended one (different heat range). • Never short circuit H.T coil primary wire to ground. It could lead to ECU failure. • Do not adjust spark plug gap with any instruments like screw driver, pliers etc.
7-7 ELECTRICAL SYSTEM Do’s and Dont’s Lights Do's • Ensure that there is no dust and water entry in bulb housing. • Ensure that all fixing screw of bulb housing are intact. • Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is intact. • Check DC Voltage Regulator’s output voltage periodically. Ensure that voltage is within specified limits. • Check that couplers and wires of bulbs are in good condition. Dont’s • Do not install a lower / higher capacity battery than what is recommended. • While washing vehicle do not direct pressurized water jet on Head Light, Tail Light, Indicators. • Do not drive the vehicle by keeping brake pedal pressed. • Do not start Vehicle with light control switch in ON condition switches Do‘s • Always clean switch assembly with soft cloth. • After washing the vehicle ensure to apply dry air on switches before operation. • Ensure that rear brake switch is free from dust, dirt and mud accumulation. • Always ensure that grommets provided on clutch switch, front brake switch and rear brake switch are intact. • Always apply WD-40 electrical contact cleaning spray to sticky switches. Dont’s • Do not apply direct pressurized water jet on control switches. • Do not lubricate electrical switches by oil or grease. • Do not over tighten the switches. • Do not add extra electrical loads e.g. musical horns, additional horns, buzzers as it will reduce switch contact life and battery life and battery life. • Do not tamper / alter rear brake switch spring. • Do not operate switch immediately after water servicing.
7-8 ELECTRICAL SYSTEM Electrical Checking System Sr.No. Fuse Effect of Fuseblowing No & Rating Description 1 N/A N/A N/A 2 F2-7.5 Amp Electrical cluster Primary Speedo cluster will not work. Secondary Speedo work. 3 F3-15 Amp Main relay Contacts + ECU ECU function OFFand Main relay do not get ON. 4 F4-15 Amp Kill Switch + HT Coil 12V Supply to H.T. coils is disconnected ignition system will not work. 5 F5-15 Amp Radiator Fan Radiator fan motor not working. 6 F6-15 Amp Lighting All lightings (Head light, indicator, tail light, horn) do not work and vehicle getstart. 7 F7-7.5 Amp Engine Kill Switch Input Engine Kill Switch and ECU is disabled enginecannotstart. 8 F8-7.5 Amp Speedometer Primary, Secondary Speedometer don’t work. 9 F9-7.5 Amp ABS 9MECU ABS System will not work, ABS indicator remains ON and vehicle speed is not indicated in speedometer. Applicability Matrix And Malfunctioning Effect • Effect it ABS Fuse (10A) and (15A) is blown off : ABS Fuse 10A - for Solenoid. ABS Fuse 15A - for Pump. Location : Near Fuse Box. • Effect : ABS do not work. ABS indication continuous ON in speedometer. Vehicle will work as a normal disc brake vehicle. • Effect it Fuse in (Fuse Box Assembly) is blown off.
7-9 ELECTRICAL SYSTEM Electrical Checking System • Checking Procedure : Fuse 7.5A, 10A and 15A are located inside the main fuse box as shown in photograph. • ABS Fuse 10A and 15A Location : It is located near main fuse box as shown in photograph. • All fuses will be accessible as shown in photograph. • To open main fuse box cover. Press lock provided on RH side of fuse box and lift the fuse box cover as shown in photograph. Lift Press
7-10 ELECTRICAL SYSTEM Electrical Checking System OR • Remove fuse by nose plier as shown in photograph. • On vehicle : Check the continuity of fuse with Digital multi meter. Continuity shown - Fuse ok. No Continuity - Fuse blown off. If it is blown off, replace by new one of same capacity. • ABS fuses will be accessible as shown in photograph • Check continuity as shown in photograph. • To open ABS fuse box cover. Press both sides simultaneously and lift ABS fuse box cover as shown in photograph. Lift Press Press
7-11 ELECTRICAL SYSTEM SOP : • Switch OFF ignition key. • Disconnect ignition switch’s coupler. • Check continuity between wires in ‘ON’ and ‘OFF’ position. Standard • Beep Sound and Continuity in ‘ON’ position. No continuity in ‘OFF’ position. Measuring And Testing Equipment : Multimeter SOP : • Put ignition switch OFF. • Put kill switch OFF. • Set multimeter at continuity range. • Connect multimeter as shown in the table. Meter Range Connections Continuity Check Continuity Mode Meter +ve Meter -ve OFF - No continuity Brown wire White wire ON - Continuity Measuring And Testing Equipment : Multimeter SOP : • Turn ‘ON’ the ignition switch. • The brake light LED bank should glow brightly when the front brake lever is pressed. • If it does not, check the front brake switch. Brown Blue Continuity check bymultimeter Lever Pressed l l Continuity isshown Lever Released l l No Continuity Meter Range Wire Connection Condition Result Meter +ve Meter -ve Engine ON condition Continuity is shown Continuity mode Grey / Red wire Brown / Blue wire Engine OFF Condition No Continuity Front Brake Light Switch Kill Switch Electrical Checking System Ignition Switch Measuring And Testing Equipment : Multimeter
Meter Range Yellow / Green Black / Yellow Lever Pressed l l Lever Released l l Brown Blue Continuity check by multimeter Brake Pedal Pressed l l Continuity Is shown Brake Pedal Released l l No continuity 7-12 ELECTRICAL SYSTEM Electrical Checking System Measuring And Testing Equipment : Multimeter SOP : • Turn ‘ON’ the ignition switch. • Check the operation of the rear brake light switch by depressing the brake pedal. • If it does not operate, check continuity of rear brake switch. Measuring And Testing Equipment : Multimeter SOP : Check continuity of clutch switch as follows. Clutch Brake Light Switch Rear Brake Light Switch Termination Unit Function • It has transit diode for filtration of voltage surge / ripple in mains supply line there by protect ECU from voltage fluctuations. • It also consist of two diodes that are used for clutch switch and neutral switch circuit. • These diodes are called as reverse protection diode. • These reverse protection diodes provide correct neutral indication in speedo console. • Symptoms of malfunctioning : Glowing of neutral indication in speedo console when vehicle is in gear and on pressing of clutch lever. No checking method is recommended using Multimeter Note :
7-13 ELECTRICAL SYSTEM Electrical Checking System Horn • Measuring And Testing Equipment : DC Clamp Meter SOP : • Encircle clamp meter jaws around Brown wire of horn. • Press horn switch and check instantaneous current drawn by horn. Clamp Meter Range Connections Standard Value 200DC A Encircle clamp meter jaws around Brown wire of horn 2.2 Amps Fuel Gauge - Tank Unit Measuring And Testing Equipment : Multimeter Meter Range Connections Standard Value 200 Ohms Meter +ve Meter -ve Asper chart Pink or Red Green or Red given below Resistance (+ 2 ohm) Bars on Speedometer 12 8 32 7 42 6 52 5 62 4 72 3 82 2 92 1 Standard Value : FullTank EmptyTank If display in speedo console is not proper then please check following : • Battery Voltage • Speedometer coupler and fuel gauge tank unit coupler connection is firm. Note
7-14 ELECTRICAL SYSTEM Starter Relay Location : Mounted on chassis in RHS seat cowling near relays. Meter Range Connections Standard Value 200 Ohms Meter +ve Meter -ve 3.9 Ohms + 10% Starter Relay Coil Red - Yellow Wire Starter Relay Coil Black Wire SOP : • Switch OFF engine. • Disconnect coupler from Relay. • Connect multi meter to Starter Relay coil terminals. Starter Relay Continuity Checking Measuring And Testing Equipment : Multimeter SOP : • Connect external 12V DC supply to starter relay coil terminals. • ‘Tuk’ sound will be heard. • Set multi meter on continuity mode. • Connect multi meter at relay contact terminals. • Continuity (beep sound) indicates starter relay is OK. Starter Relay Coil Resistance Checking Measuring And Testing Equipment : Multimeter Electrical Checking System.
7-15 ELECTRICAL SYSTEM Electrical Checking System Spark Plug • LHS & RHS Spark Plug - Maker : Champion / BOSCH Type : RG6HCC / UR6CE Signal from twin output H.T COIL 2. • Central Spark Plug - Maker : Champion / BOSCH Type : RER6YCA / YR5NEO Signal from single output H.T COIL 1. • Spark Plug Gap 0.8 ~ 0.9 mm • Clean and adjust frequency - every 20000 Km / H. Spark Plug Cap : • Central spark plug cap. • LHS spark plug cap. • RHS spark plug cap. 0.8 mm to 0.9 mm Central LHS RHS
7-16 ELECTRICAL SYSTEM Electrical Checking System Stator Plate Battery Charging Coil This is 3 phase starter winding (oil dipped type) Number of poles - 18 Coils : Battery charging coil SOP : • Disconnect magneto coupler. • Set multimeter at 200 Ohm range. • Connect multimeter as shown in table and note reading. Regulator Rectifier (RR) Unit Location : On frame LH side (Inside LH seat cowl) Function : • This is 3 phase RR unit and it convert 3 phase AC voltage generated by magneto to DC voltage and also DC voltage is regulate at 14.5 V + 0.2 V DC at all engine speeds. • This voltage is used for charging of 8 Ah VRLA battery. SOP : • Remove spark plug cap from HT Coil Cable. • Set multi meter on 2 K Ohm range. • Connect multi meter probes as shown in photograph. • Standard value,1 K Ohm + 150 Ohm. Sr. Meter Range Connections Standard Resistance Meter +ve Meter -ve Value 1 200 Ohm Y1 Y3 2 Y2 Y2 1 Ohm 3 Y3 Y1
7-17 ELECTRICAL SYSTEM Electrical Checking System Starter Motor - Current Drawn Location : Above crankcase joining area. SOP : • Remove lower fairing LH and RH by removing 6 nos. each phillips screws. • Disconnect all 2 spark plug caps (care to be taken so that spark plug does not jump to metal part). • Switch ‘ON’ Ignition switch and kill switch. • Select range and set clamp meter zero reading. • Encircle red input wire of starter motor by clamp meter jaws. • Crank the engine by pressing self starter button. • Press self starter button for 3 seconds and check cranking current displayed. Meter Range Connections Standard Value 200 DC A Encircle clamp meter transformer jaws around thick red wire of starter motor 75 ~ 80 Amps spark plug caps removed Flasher Location : Beneath pillion seat near termination unit. No checking method. Try by replacement.
7-18 ELECTRICAL SYSTEM Electrical Checking System Location Relays : 1. Main Relay : Main relay is switched ON by ECU giving GND signal to main relay for completing coil circuit. Main relay contacts output is used for : • Ignition Circuit • Fuel pump Circuit • Starter Motor Circuit • Side Stand Circuit • Radiator fan Motor Circuit • Fuel injector Circuit • Purge Valve Circuit • MIL Indication Circuit • Engine RPM Indication Circuit • Purge Valve Circuit If this relay fails, then the vehicle will not start. 2. Radiator Fan Motor Relay : This relay is used for switching ON / OFF radiator fan motor. The fan motor power is 30W and hence to avoid 2.5A DC current flowing through wiring harness, radiator relay is fitted. 3. Fuel Pump Relay : Fuel pump motor power is 18W. This motor is of continuous duty type and as long as the vehicle is running the fuel pump module will remain ON and 1.6A Max current will continuously flow through wiring harness. To avoid this fuel pump relay is provided. 4. Intermedia Relay : This relay is used in starter motor to switch ON starter relay. Sr. No Relays Location 1 2 3 4 Main Relay Radiator Relay Fuel Pump Relay Intermediate Relay Mounted on frame tube bracket inside seat cowling RHS.
7-19 ELECTRICAL SYSTEM Standard Operating Procedure Headlight Assembly Removal • Remove side mask mounting screws (4nos.) with metal and plastic washer (metal washer outside). • Remove wind shield mounting Allen bolts (4nos.). Take out wind shield.
Standard Operating Procedure • Ensure that (4 nos.) well nuts on headlight fairing are in the good condition. • Remove headlight assembly hardware as follows : 1. Bottom side bolts (2 nos.) with plastic washer. 2. Screws (4 nos.) with metal washer. 7-20 ELECTRICAL SYSTEM • Ensure that (4 nos.) well nuts on headlight fairing are in the good condition. • LH & RH side mask. Take Out
Standard Operating Procedure • Headlight assembly from fairing. 7-21 ELECTRICAL SYSTEM • Pull out headlight assembly from headlight assembly mounting bracket. • Unplug headlight assembly coupler connector and take out headlight assembly. • Remove headlight assembly mounting screws (3nos.) with metal washers by Philips head screw driver. • Take out headlight assembly from fairing.
7-22 ELECTRICAL SYSTEM Standard Operating Procedure Tail Lamp Assembly Removal 1. Remove pillion rider seat. 4. Remove rear fender top side bolts (2 nos.) [A] and screws (3 nos.) [B] with 10 mm spanner & phillips head screw driven. Headlight Focus Adjustment • Adjust headlight adjustment bolt with the help of attachment from FORCE make socket tool box in handle bar turned towards RH side condition. 2. Remove LH and RH grab handles mounting bolts (4 nos.) with 6 mm Allen key. 3. Take out grab handle. 1 3 A 2 10 mm socket Ratchet Extension Rod 4 A B
Standard Operating Procedure • Unplug tail lamp coupler connector. • Unplug LH side rear indicator connector. Remove • Rear fender bottom side 2 bolts with metal washer and 2 screws. • Unplug rear number plate lamp connector. 7-23 ELECTRICAL SYSTEM • Unplug RH side rear indicator connector. • Tail Lamp, LH side indicator, RH side indicator : Group assembly coupler connector.
7-24 ELECTRICAL SYSTEM Standard Operating Procedure • Remove rear fender reinforcement bracket bolt. • Rear fender mounting bolts (2 nos.) • Pull out rear fender as shown in photograph. • Remove seat lock cable lock plate. • Remove seat lock cable seat lock plate from cable holder.
Standard Operating Procedure • Remove tail lamp screw (4 nos.) and take out tail lamp. • Remove seat lock cable from seat lock. • Remove pillion rider seat and rear number plate mounting bracket nuts (2 nos.) with 10mm T-spanner. 7-25 ELECTRICAL SYSTEM • Take out rear fender.
7-26 ELECTRICAL SYSTEM Standard Operating Procedure • Take out rear mud flap fender • Take out rear number plate mounting bracket. • Remove rear mud flap mounting screw. • Remove rear under tray mounting bolts (6 nos.).
Standard Operating Procedure • Pull out rubber (black) and remove indicator coupler connection. • Take out rear under tray. • Remove front under tray mounting screws (2 nos.) for easy removal and fitment of indicator wire. • Remove indicator wire as shown in photograph. 7-27 ELECTRICAL SYSTEM
Pull Out • Pull out indicator nut and washers. Rear Fender Removal • Remove nut lock (4nos.) rear reflector with 8 mm spanner. • Remove indicator mounting nut with 15 mm spanner. • Take out indicator wire from reinforcement bracket. • Remove rear number plate lamp coupler from rear fender reinforcement. 7-28 ELECTRICAL SYSTEM Standard Operating Procedure
7-29 ELECTRICAL SYSTEM Standard Operating Procedure • Remove rear number plate lamp (2nos.) • Take out rear number plate lamp • Remove rear fender reinforcement bracket screw. • Remove rear fender reinforcement.
7-30 ELECTRICAL SYSTEM Standard Operating Procedure • Remove seat lock cable mounting bracket. • Remove seat lock plate. • Remove seat lock.
7-31 ELECTRICAL SYSTEM Standard Operating Procedure • Remove battery and rubber case. ECU / Battery Case Removal • Fuse box assembly. • Remove battery case mounting bolts (4 nos.). • Lift battery case along with ECU. • Remove ECU mounting bracket nut (4nos.) with 10 mm spanner and take out ECU mounting bracket.
7-32 ELECTRICAL SYSTEM Standard Operating Procedure • Till it become perpendicular to grey part. • Pull ECU lock as shown in photograph. • Pull ECU lock a shown in pictures. • Remove battery case.
7-33 ELECTRICAL SYSTEM Standard Operating Procedure • Fit ECU in coupler completely and apply lock. Secondary speedometer replacement • Remove petrol tank cover. • Ensure that coupler and ECU “Top” written face should be facing upward. ECU Fitment • Take out ECU. Push Press
7-34 ELECTRICAL SYSTEM Standard Operating Procedure • Remove secondary speedometer screw (2 nos.). • Take out secondary speedometer. Roll Over Sensor Removal • Remove wire connector. • Remove roll over sensor mounting bracket bolts (2 nos.). • Take out roll over sensor mounting bracket.
7-35 ELECTRICAL SYSTEM Standard Operating Procedure • Take out separate out roll over sensor and its mounting plate. • Remove roll over sensor mounting nuts (2 nos.) holding screw with Philips head screwdrivers.
VRLA BATTERY8Ah + - R B MAGNETOASSEMBLY Y Y Y Y Y Y B B REGULATORUNIT B Y W/B REGULATOR EARTH BR/L W/B WF2W/B PIN 3 PIN 5 PIN 6 Gr/Pi G/WG/RG/R WGr/Pi G/W PIN1 PIN 10 PIN 19 PIN 20 IGNITIONSWITCH W F8 FUSEI/P O/Gr Br/L SPEEDOMETER2 KILL SWITCH SUPPLY GROUND LOW BATTERY IND. I/P SPEEDOMETER1 LOW BATTERY IND. O/P BATTERY KILLSWITCH GROUNDND Location onstarter relay F1 30AR W/B O/Gr G/W G/R G/R WO/Gr G/W Br ON OFF B R Y Y R Y Y W/B Y 7-36 ELECTRICAL SYSTEM Battery Charging & Low Battery Indication Circuit
7-37 ELECTRICAL SYSTEM Ignition Circuit IGNITION SWITCH W BR/L W/B ON OFF Br ENGINE TEMP SENSOR Pi/L Y/W VRLA BATTERY - 8Ah + R - B TPS Y/B G/Y R/L Pi Y/B R/L SIDE STAND SWITCH Pi Y R KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R ROLL OVER SENSOR Gr B/Y Br/G R/L Y/B Br/G B/Y W/R B/Y W/R H.T. COIL 1 B/Y B O/W H.T. COIL 2 B/Y O/W B/R ECU Ignition Driver 2 Crankshaft Input (+) Main Relay Driver Throttle Position Sensor Engine Temp Sensor I/P Sensor Ground 1 Side Stand Switch Roll Over Switch Sensor Ground 2 Ignition Keys Sensor Supply 2 Crankshaft Input (-) Power Supply After Main Relay Ignition Driver Power Ground 2 Pi/L Pi Br/G Y/B Gr/Pi R/L B/Y Br/W B B/Y 44 40 39 38 33 27 26 25 24 23 2 4 11 18 19 B/R W/R L/G G/Y Y/W MAIN FUSE BOX F1 F4 F7 7.5A 30A FUSE O/P FUSE I/P R Br/L W/B O/W Gr/R 15A F3 R/W 15A Br/W R/W R/W L/G MAIN RELAY CRANK ANGLE SENSOR Br/L W/B
7-38 ELECTRICAL SYSTEM Horn Circuit VRLA BATTERY - 8Ah + - R B HORN B Br IGNITION SWITCH ON OFF W Br BR/L W/B HORN SWITCH (CONTROL SWITCH LH) B/Y B B/Y B MAIN FUSE BOX F1 F6 30A FUSE O/P FUSE I/P R W/B Br 15A Br/L
7-39 ELECTRICAL SYSTEM Brake Lamp Circuit IGNITION SWITCH ON OFF W Br BR/L W/B MAIN FUSE BOX F1 F6 30A FUSE O/P FUSE I/P R W/B Br 15A Br/L VRLA BATTERY - 8Ah + - R B REAR BRAKE SWITCH L Br L Br FRONT BRAKE SWITCH L Br L Br L B/Y L B/Y BRAKE LAMP
7-40 ELECTRICAL SYSTEM Fuel Pump Circuit IGNITION SWITCH W BR/L W/B ON OFF Br ECU Main Relay Driver Fuel Pump Relay Roll Over Switch Sensor Ground 2 Ignition Keys Sensor Supply 2 Power Supply After Main Relay Power Ground Br/G Y/B Gr/Pi R/L Br/W B/Y 39 38 33 27 25 23 11 14 L/G W/L MAIN FUSE BOX F1 F4 F7 7.5A 30A FUSE O/P FUSE I/P R Br/L W/B O/W Gr/R 15A F3 R/W 15A Br/L W/B KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R ROLL OVER SENSOR Gr B/Y Br/G R/L Y/B Br/G Br/W R/W R/W L/G MAIN RELAY O/W O/L Gr/Pi W/L FUEL PUMP RELAY VRLA BATTERY - 8Ah + - R B B /Y O/L FUEL PUMP
7-41 ELECTRICAL SYSTEM Starter Motor Circuit LG 5 4 3 2 6 1 N GEAR INDICATOR SWITCH IGNITION SWITCH W BR/L W/B ON OFF Br MAIN FUSE BOX F1 F7 7.5A 30A FUSE O/P FUSE I/P R Br/L W/B Gr/R F3 R/W 15A W/B CONTROL SWITCH RH G r/R B r/L ON OFF G r/P i G r/R R /Y Y /R START SWITCH KILL SWITCH Br/W R/W R/W L/G MAIN RELAY Y/R R/Y R/G Gr/Pi INTERMEDIATE STARTER RELAY B/Y Y/G CLUTCH SWITCH B/Y Y/G TERMINATION UNIT Gr/Pi Y/G VRLA BATTERY - 8Ah + R - B STARTER RELAY R M STARTER MOTOR R B R/Y B/Y R/Y R ECU Starter Relay Main Relay Driver Neutral Switch Clutch Switch I/P Can High Can Low Ignition Key Y/G G/L Y/L Gr/Pi 42 37 36 33 10 11 22 R/G L/G LG F8 Y/Br 7.5A Br/L LG SPEEDOMETER 2 IGNITION SUPPLY W Y/Br G/L Y/L G/W PIN 2 CAN LOW PIN 11 PIN 12 BATTERY POSITIVE PIN 1 CAN HIGH PIN 10 COMMON GROUND W Y/Br G/L Y/L G/W SPEEDOMETER 1 IGNITION SUPPLY W Y/Br G/L Y/L G/W PIN 2 CAN LOW PIN 9 PIN 10 BATTERY POSITIVE PIN 1 CAN HIGH PIN 8 COMMON GROUND W Y/Br G/L Y/L G/W Power Supply After Main Relay Br/W 25 Power Ground 2 B/Y 23 F2 7.5A W W/B 1 B/Y Power Ground 1
7-42 ELECTRICAL SYSTEM Side Stand Circuit KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R SPEEDOMETER 2 IGNITION SUPPLY W Y/Br G/L Y/L G/W PIN 2 CAN LOW PIN 11 PIN 12 BATTERY POSITIVE PIN 1 CAN HIGH PIN 10 COMMON GROUND W Y/Br G/L Y/L G/W SPEEDOMETER 1 IGNITION SUPPLY W Y/Br G/L Y/L G/W PIN 2 CAN LOW PIN 9 PIN 10 BATTERY POSITIVE PIN 1 CAN HIGH PIN 8 COMMON GROUND W Y/Br G/L Y/L G/W BR/L W/B VRLA BATTERY - 8Ah + R - B Pi Y/B R/L SIDE STAND SWITCH Pi Y R ECU Main Relay Driver Side Stand Switch Sensor Ground 2 Can High Can Low Sensor Supply 2 Power Supply After Main Relay Power Ground 2 Pi Y/B G/L Y/L R/L Br/W B/Y 40 38 37 36 27 25 23 11 L/G Br/W R/W R/W L/G MAIN RELAY MAIN FUSE BOX F1 30A R W/B IGNITION SWITCH W ON OFF Br F3 F8 7.5A FUSE O/P FUSE I/P Br/L R/W Y/Br 15A F2 7.5A W W/B W/B F7 7.5A Gr/R Br/L Ignition Key 33 Gr/Pi 1 Power Ground 1 B/Y
7-43 ELECTRICAL SYSTEM Radiator Fan Motor Circuit VRLA BATTERY - 8Ah + R - B ECU Main Relay Driver Engine Temp Sensor I/P Can High Can Low Ignition Key Radiator Fan Relay Power Supply After Main Relay G/L Y/L Gr/Pi G/B Br/W 37 36 33 32 25 11 L/G Y/W KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R Br/W R/W R/W L/G MAIN RELAY MAIN FUSE BOX F2 F5 F7 7.5A 7.5A FUSE O/P FUSE I/P R Br/L W/B O Gr/R 15A F3 15A R/W W/B W/B BR/L W/B Y/Br Y/L PIN 10 PIN 11 Y/Br Y/Br Y/L PIN 1 PIN 2 PIN 8 G/W Y/Br Y/L GR/Y O Br/W G/B RADIATOR FAN RELAY G r/Y B /Y 19 COOLANT TEMP SENSOR Pi/L Y/W F1 30A F8 7.5A Y/Br Br/L W W/B PIN 10 G/L G/L PIN 9 W W PIN 2 PIN 1 W W G/L G/L CAN INTERFACE B/Y G/L Y/L PIN 12 Y/L G/W G/W Gr/Pi PIN 11 G/W Gr/Pi 44 23 Sensor Ground 1 Pi/L Power Ground 2 B/Y IGNITION SWITCH W ON OFF Br SPEEDOMETER 2 CAN HIGN CAN LOW SPEEDOMETER 1 BATTERY POSITIVE IGNITION SUPPLY CAN HIGN RADIATOR FAN MOTOR R B COMMON GROUND CAN LOW IGNITION SUPPLY BATTERY POSITIVE COMMON GROUND KILL SWITCH INPUT 1 Power Ground 1 B/Y
7-44 ELECTRICAL SYSTEM Side Indicator Circuit B/Y G G B/Y MAIN FUSE BOX F2 F8 7.5A 7.5A FUSE O/P FUSE I/P Br/L W Y/Br IGNITION SWITCH BR/L W/B Gr B/Y Gr B/Y G B/Y G B/Y B/Y Gr B/Y Gr VRLA BATTERY - 8Ah + R - B LED - FLASHER O B r B /Y SIDE INDICATOR SWITCH (CONTROL SWITCH LH) G O Gr L OFF R G O Gr F6 15A W/B Br Br/L SPEEDOMETER 1 RIGHT TURN INDICATOR LEFT TURN INDICATOR W Y/Br Gr G G/W PIN 5 PIN 6 COMMON GROUND PIN 10 IGNITION SUPPLY PIN 2 BATTERY POSITIVE PIN 1 W Y/Br Gr G G/W F1 30A W/B R O B r B /Y SPEEDOMETER 2 COMMON GROUND W Y/Br G/W PIN 12 IGNITION SUPPLY PIN 2 BATTERY POSITIVE PIN 1 W Y/Br G/W W ON OFF Br DIR IND FRONT RH DIR IND FRONT LH DIR IND REAR RH DIR IND REAR LH
7-45 ELECTRICAL SYSTEM Fuel Meter Circuit W Y/Br W/Y SPEEDOMETER 2 BATTERY POSITIVE IGNITION SUPPLY W Y/Br PIN 1 PIN 2 COMMON GROUND PIN 12 G/W SPEEDOMETER 1 BATTERY POSITIVE FUEL LEVEL (TFR I/P SIG) W W/Y PIN 1 PIN 3 COMMON GROUND PIN 10 G/W G/W W G/W F1 30A FUSE O/P FUSE I/P R W/B VRLA BATTERY - 8Ah + R - B IGNITION SWITCH BR/L W/B Br G /R FUEL PUMP P i/R W/Y G /W F2 7.5A W/B W MAIN FUSE BOX W ON OFF Y/Br Y/Br PIN 2 IGNITION SUPPLY F8 Y/Br 7.5A Br/L
7-46 ELECTRICAL SYSTEM Fuel Injector Circuit IGNITION SWITCH W BR/L W/B ON OFF Br VRLA BATTERY - 8Ah + R - B TPS Y/B G/Y R/L KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R B/Y W/R B/Y W/R ECU Crankshaft Input (+) Injector Driver Main Relay Driver Throttle Position Sensor Sensor Ground 2 Ignition Keys Sensor Supply 2 Crankshaft Input (-) Power Ground 2 Power Supply After Main Relay Y/B Gr/Pi R/L B/Y B/Y Br/W 38 33 27 26 23 25 4 5 11 18 W/R B/W L/G G/Y Br/W R/W R/W L/G MAIN RELAY CRANK ANGLE SENSOR MAIN FUSE BOX F1 F7 7.5A 30A FUSE O/P FUSE I/P R Br/L W/B Gr/R F3 R/W 15A W/B FUEL INJECTOR B /W B r/W
7-47 ELECTRICAL SYSTEM Purge Valve Circuit IGNITION SWITCH W BR/L W/B ON OFF Br VRLA BATTERY - 8Ah + R - B TPS Y/B G/Y R/L KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R Br/W R/W R/W L/G MAIN RELAY MAIN FUSE BOX F1 F7 7.5A 30A FUSE O/P FUSE I/P R Br/L W/B Gr/R F3 R/W 15A W/B ENGINE TEMP SENSOR Pi/L Y/W ECU Main Relay Driver Throttle Position Sensor Engine Temp Sensor I/P Sensor Ground 1 Sensor Ground 2 Canister Purge Valve Ignition Keys Sensor Supply 2 Power Supply After Main Relay Power Ground 2 Pi/L Y/B G/Pi Gr/Pi R/L Br/W B/Y 44 38 34 33 27 25 23 11 18 19 L/G G/Y Y/W PURGE VALVE G /P i B r/W
7-48 ELECTRICAL SYSTEM MIL Indication Circuit KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R VRLA BATTERY - 8Ah + R - B ECU Can High Can Low Ignition Key Power Supply After Main Relay Power Ground 2 G/L Y/L Gr/Pi Br/W B/Y 37 36 33 25 23 IGNITION SWITCH W BR/L W/B ON OFF Br Br/W R/W R/W L/G MAIN RELAY MAIN FUSE BOX F1 F3 15A 30A R W/B F2 7.5A W W/B 11 Main Relay Driver L/G F7 7.5A Y/Br Br/L FUSE O/P FUSE I/P F8 7.5A Gr/R Br/L R/W W/B SPEEDOMETER 2 IGNITION SUPPLY W Y/Br G/L Y/L G/W PIN 2 CAN LOW PIN 11 PIN 12 BATTERY POSITIVE PIN 1 CAN HIGH PIN 10 COMMON GROUND W Y/Br G/L Y/L G/W SPEEDOMETER 1 IGNITION SUPPLY W Y/Br G/L Y/L G/W Gr/Pi PIN 2 CAN LOW PIN 9 PIN 10 BATTERY POSITIVE PIN 1 CAN HIGH PIN 8 COMMON GROUND W Y/Br G/L Y/L G/W Gr/Pi PIN 11 KILL SWITCH INPUT 1 Power Ground 1 B/Y
7-49 ELECTRICAL SYSTEM Low Oil Pressure Indication Circuit W Y/Br Br/Pi SPEEDOMETER 2 BATTERY POSITIVE IGNITION SUPPLY W Y/Br PIN 1 PIN 2 COMMON GROUND PIN 12 G/W SPEEDOMETER 1 BATTERY POSITIVE OIL PRESSURE SWITCH W Br/Pi PIN 1 PIN 4 COMMON GROUND PIN 10 G/W G/W W Y/Br G/W Y/Br PIN 2 IGNITION SUPPLY OIL PRESSURE SENSOR Br/Pi VRLA BATTERY - 8Ah + R - B F1 30A FUSE O/P FUSE I/P R W/B F8 7.5A IGNITION SWITCH W BR/L W/B OFF Br F2 7.5A W/B W MAIN FUSE BOX Y/Br Br/L ON
7-50 ELECTRICAL SYSTEM Engine RPM Indication Circuit G /R FUEL PUMP P i/R W/Y G /W H.T. COIL 1 B/Y B O/W H.T. COIL 2 B/Y O/W B/R VRLA BATTERY - 8Ah + R - B BR/L W/B B/Y W/R B/Y W/R CRANK ANGLE SENSOR KILL SWITCH (CONTROL SWITCH RH) G r/R B r/L ON OFF G r/P i G r/R ECU Crankshaft Input + E ngine S peed O/P Main Relay Driver Can High Can Low Ignition Key Crankshaft Input - Power Supply After Main Relay G/L Y/L Gr/Pi B/Y Br/W 37 36 33 26 25 4 7 11 W/R B/V L/G MAIN FUSE BOX F1 30A FUSE O/P FUSE I/P R W/B F3 15A R/W Br/W R/W R/W L/G MAIN RELAY W/B HEAD LAMP ASSEMBLY B/V F2 7.5A W/B W Gr/Pi R R/B R/Y L/B B/Y Br W Y/Br G/L Y/L PIN 2 PIN 10 PIN 11 W Y/Br G/L Y/L PIN 1 G/W PIN 12 G/W W Y/Br R G/L PIN 2 PIN 7 PIN 8 W Y/Br R G/L PIN 1 Y/L PIN 9 Y/L G/W PIN 10 G/W Gr/Pi PIN 11 Gr/Pi Ignition Driver B 24 2 Ignition Driver 2 B/R Power Ground 2 B/Y 23 PIN 3 W/Y W/Y 1 Power Ground 1 B/Y CAN HIGH CAN LOW IGNITION SUPPLY BATTERY POSITIVE COMMON GROUND SPEEDOMETER 2 HIGH BEAM INDICATOR CAN HIGH IGNITION BATTERY POSITIVE CAN LOW COMMON GROUND KILL SWITCH INPUT SPEEDOMETER 1 IGNITION SWITCH W ON OFF Br F7 7.5A Gr/R Br/L IGNITION SWITCH ENGINE RPM B/Y B/V F8 Y/Br 7.5A Br/L Br GND R/B R/Y R HIGH BEAM INDICATION KILL SWITCH INPUT Gr/Pi V F6 15A Br Br/L F4 O/W 15A Br/L FUEL LEVEL (TFR I/P SIGNAL)