7-12 ELECTRICAL SYSTEM Electrical Checking System Rear Brake Light Switch Measuring & 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. Brown Blue Continuity check bymultimeter Brake Pedal Pressed l l Continuity is shown Brake Pedal Released l l No continuity Meter Range Yellow / Green Black / Yellow Lever Pressed l l Lever Released l l Measuring & Testing Equipment : Multimeter SOP : • Check continuity of clutch switch as follows. 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 & 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 & on pressing of clutch lever. Note : 1. No checking method is recommended using Multimeter Clutch Brake Light Switch
7-13 ELECTRICAL SYSTEM Electrical Checking System Horn • Measuring & Testing Equipment : DC Clamp Meter SOP : • Encircle clamp meter jaws around Brown wire of horn. • Press horn switch & check instantaneous current drawn by horn. Clamp Meter Range Connections Standard Value 200 DCA Encircle clamp meter jaws around Brown wire of horn 2.2 Amps Fuel Gauge - Tank Unit Measuring & Testing Equipment : Multimeter Meter Range Connections Standard Value 200 Ohms Meter +ve Meter -ve As per chart givenbelow Pink / Red Green / Red Empty Tank FullTank Note : If display in speedo console is not proper then please check following : • Battery Voltage • Speedometer coupler & fuel gauge tank unit coupler connection is firm. Resistance (+ 2 ohm) Bars on Speedometer 12 8 32 7 42 6 52 5 62 4 72 3 82 2 92 1 Standard Value : Full
7-14 ELECTRICAL SYSTEM Electrical Checking 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 & 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 & Testing Equipment : Multimeter
7-15 ELECTRICAL SYSTEM Electrical Checking System Spark Plug • LHS spark plug - Maker : Champion / BOSCH Type : RG6HCC / UR6CE Signal from single 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 & adjust frequency - every 20,000 Kms. Spark Plug Cap • Central spark plug cap. • LHS spark plug cap. Central LHS
7-16 ELECTRICAL SYSTEM Electrical Checking System 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 Meter +ve Meter -ve Resistance Value 1 200 Ohm Y1 Y2 2 Y2 Y3 1 Ohm 3 Y3 Y1 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 & note reading. Regulator Rectifier (RR) Unit Location : On frame LH side (Inside LH seat cowl) Function : • This is 3 phase RR unit & it convert 3 phase AC voltage generated by magneto to DC voltage & 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.
7-17 ELECTRICAL SYSTEM Electrical Checking System Starter Motor - Current Drawn Location : Above crankcase joining area. Meter Range Connections Standard Value 200 DCA Encircle clamp meter transformer jaws around thick Red wire of starter motor 75 ~ 80 Amps Spark plug capsremoved SOP : • Remove lower fairing LH & 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 & kill switch. • Select range & 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 & check cranking current displayed. Flasher Location : Beneath pillion seat near termination unit. No checking method. Try by replacement.
7-18 ELECTRICAL SYSTEM Electrical Checking System Sr.No Relays Location 1 Main Relay Mounted on frametube 2 Fan Relay bracket inside seatcowling 3 Fuel PumpRelay RHS 4 IntermediateRelay 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 & hence to avoid 2.5ADC 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 & as long as the vehicle is running the fuel pump module will remain ON & 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.
7-19 ELECTRICAL SYSTEM Standard Operating Procedure Headlight Assembly Removal Take out wind shield. Remove side mask mounting screws (4nos.) with metal & plastic washer (Metal washer outside). Remove wind shield mounting screws (4nos.).
Standard Operating Procedure Ensure that (4 nos.) well nuts on headlight fairing are in the good condition. • Headlight assembly hardware as follows : - Bottom side bolts (2 nos.) with plastic washer. - 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 Remove
Standard Operating Procedure Headlight assembly from fairing. 7-21 ELECTRICAL SYSTEM Pull Out Headlight assembly from headlight assembly mounting bracket. Remove Headlight assembly coupler connector & take out headlight assembly. Remove Headlight assembly mounting screws (3nos.) with metal washers by phillips head screw driver. Take Out Headlight assembly from fairing.
7-22 ELECTRICAL SYSTEM Standard Operating Procedure Tail Lamp Assembly Removal Remove • LH & RH grab handles mounting bolts (4 nos.) with 6 mm allen key & take out grab handle. Remove • Rear fender top side bolts (2 nos.) [A] with 10 mm spanner & screws (3 nos.)[B] with phillips head screw driven. 10mm socket Extensionrod Ratchet 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. • Using the tool as shown as picture to adjust headlight adjustment. • Take out grab handle.
Standard Operating Procedure • Tail lamp assembly. • RH side rear indicator. • LH side rear indicator. Take Out Remove • Rear fender bottom side 2 bolts with metal washer & 2 screws. • Rear number plate lamp. 7-23 ELECTRICAL SYSTEM
7-24 ELECTRICAL SYSTEM Standard Operating Procedure Remove Pull Out Remove • Rear fender reinforcement bracket bolt. • Rear fender mounting bolts (2 nos.) • Rear fender as shown in photograph. • Seat lock cable lock plate. • Seat lock cable seat lock plate from cable holder. Remove
Standard Operating Procedure Remove Remove • Tail lamp screw (4 nos.) . Take Out Remove • Seat lock cable from seat lock. • Pillion rider seat. • Rear number plate mounting bracket nuts (2 nos.) with 10mm T-spanner. 7-25 ELECTRICAL SYSTEM • Take out tail lamp.
7-26 ELECTRICAL SYSTEM Standard Operating Procedure Remove Remove Take Out • Rear number plate mounting bracket. Take Out • Rear mud flap mounting screw. • Rear under tray mounting bolts (4 nos.) & screws (2 nos.)
Standard Operating Procedure Remove Pull Out • Rubber (black) & remove indicator coupler connection. • Rear under tray. Take Out Remove • Front under tray mounting screws (2 nos.) for easy removal & fitment of indicator wire. • Indicator wire as shown in photograph. 7-27 ELECTRICAL SYSTEM • Remove indicator coupler connection.
Remove Pull Out • Indicator nut & washers. Rear Fender Removal Remove Remove • Nut lock (4nos.) rear reflector with 8 mm spanner. • Indicator mounting nut with 15 mm spanner. Take Out • Indicator wire from reinforcement bracket. • Rear number plate lamp coupler from rear fender reinforcement. 7-28 ELECTRICAL SYSTEM
7-29 ELECTRICAL SYSTEM Standard Operating Procedure Remove Remove Remove • Rear number plate lamp (2nos.) Take Out • Rear number plate lamp • Rear fender reinforcement bracket screw. • 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 Remove • Battery & rubber case. ECU / Battery Case Removal • Fuse box assembly. • Battery case mounting bolts (4 nos.). • Lift battery case along with ECU. Remove • ECU mounting bracket nut (4nos.) with 10 mm spanner & take out ECU mounting bracket.
7-32 ELECTRICAL SYSTEM Standard Operating Procedure Pull • Till it become perpendicular to gray part. • Pull ECU lock as shown in photograph. • ECU lock a shown in pictures. • Battery case. Remove
7-33 ELECTRICAL SYSTEM Standard Operating Procedure • Fit ECU in coupler completely & apply lock. Secondary speedometer replacement Remove • Petrol tank cover. Push Press • Ensure that coupler & ECU “Top” written face should be facing upward. ECU Fitment • Take out ECU.
7-34 ELECTRICAL SYSTEM Standard Operating Procedure Remove • Secondary speedo screw (2 nos.). Take Out • Secondary speedo. Roll Over Sensor Removal • Petrol tank. Remove 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 & its mounting plate. Remove • Roll over sensor mounting nuts (2 nos.) holding screw with phillips 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 BR/L W/B COOLANT TEMP. SENSOR VRLA BATTERY 8Ah + R TPS Y/B G/Y R/L Pi Y/B Pi/B SIDE STAND SWITCH Pi Y R KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/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 ECU Power Ground 1 Ignition Driver 2 Crankshaft Input (+) Main Relay Driver Throttle Position Sensor Engine Temp Sensor I/P Sensor Ground 1 Side Stand Switch Ignition Keys Lambda Upstrem Heater Crankshaft Input (-) Power Supply After Main Relay Ignition Driver 1 Power Ground 2 Y/B Pi Gr/Pi L/R B/Y Br/W B B/Y 44 39 33 28 26 25 24 23 1 2 4 11 18 19 B/R W/R B/Y L/G G/Y Y/W MAIN FUSE BOX Br/W R/W R/W L/G MAIN RELAY CRANK ANGLE SENSOR F1 30A W/B R H.T. COIL 2 B/Y O/W B/R Roll Over Sensor 16 Br/G 3 Sensor Supply 1 Pi/B FUEL INJECTOR B/W Br/W Injector Driver B/W 5 B/G L/R Br/W LAMBDA SENSOR L/Y Gr W W B TER HEA SENSOR Lambda Sensor 1 (LSF) 15 L/Y Sensor GND 2 (LSF1) 9 B/G R/L 27 Sensor Supply 2 IGNITION SWITCH W ON OFF Br Y/B Y/W - B F4 F7 7.5A FUSE O/P FUSE I/P Br/L O/W Gr/R 15A F3 R/W 15A Br/L W/B Location on starter relay
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 F6 FUSE O/P FUSE I/P Br 15A Br/L Location on starter relay F1 30A W/B R
7-39 ELECTRICAL SYSTEM Brake Lamp Circuit IGNITION SWITCH ON OFF W Br BR/L W/B MAIN FUSE BOX F6 FUSE O/P FUSE I/P 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 Location on starter relay F1 30A W/B R
7-40 ELECTRICAL SYSTEM Fuel Pump Circuit B/Y W/R B/Y W/R CRANK ANGLE SENSOR IGNITION SWITCH W BR/L W/B ON OFF Br ECU Power Ground 1 Main Relay Driver Fuel Pump Relay Sensor Ground 1 Ignition Keys Sensor Supply 2 Power Supply After Main Relay Power Ground Y/B Gr/Pi R/L Br/W B/Y 44 33 27 25 23 1 11 12 B/Y L/G W/L MAIN FUSE BOX F4 F7 7.5A FUSE O/P FUSE I/P Br/L O/W Gr/R 15A F3 R/W 15A Br/L W/B KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/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 Location on starter relay F1 30A W/B R Roll Over Sensor 16 Br/G Crankshaft Input (-) B/Y 26 Crankshaft Input (+) 4 W/R
7-41 ELECTRICAL SYSTEM Starter Motor Circuit ECU Main Relay Driver Neutral Switch Clutch Switch Starter Relay Ignition Keys Power Supply After Main Relay Power Ground 2 R/G Gr/Pi Br/W B/Y 35 33 25 23 11 17 21 L/G LG Y/G Power Ground 1 1 B/Y IGNITION SWITCH W BR/L W/B ON OFF Br MAIN FUSE BOX F7 7.5A FUSE O/P FUSE I/P Gr/R Br/L F3 R/W 15A W/B CONTROL SWITCH RH Gr/R Br/L ON OFF Gr/Pi Gr/R R/Y Y/R START SWITCH KILL SWITCH LG NEUTRAL SWITCH G 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 VRLA BATTERY 8Ah + R - B STARTER RELAY R M STARTER MOTOR R B R/Y B/Y R/Y R SPEEDOMETER 1 NEUTRAL SWITCH I/P KILL SWITCH LG Gr/Pi PIN 13 PIN 19 GROUND PIN 20 G/W LG O/Gr G/W F8 O/Gr 7.5A Br/L F2 7.5A BATTERY PIN 10 W W W/B W Location on starter relay F1 30A W/B R TERMINATION UNIT Gr/Pi Y/G B/Y W/B Sensor Supply 1 3 Pi/B Side Stand Switch 39 Sensor Ground 1 44 Y/B Pi Pi Y/B Pi/B SIDE STAND SWITCH Pi Y R
7-42 ELECTRICAL SYSTEM Side Stand Circuit IGNITION SWITCH W BR/L W/B ON OFF Br VRLA BATTERY 8Ah + R - B Pi Y/B Pi/B SIDE STAND SWITCH Pi Y R KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R Br/W R/W R/W L/G MAIN RELAY MAIN FUSE BOX F6 F7 7.5A FUSE O/P FUSE I/P Br/L Br Gr/R 15A F3 R/W 15A Br/L W/B SPEEDOMETER 2 IGNITION SUPPLY KILL SWITCH SUPPL Y Br Gr/Pi PIN 1 PIN 3 GROUND PIN 5 G/W PIN 7 SIDE STAND INDICATION O/Br Br O/Gr O/Br F8 7.5A O/Gr Br/L Location on starter relay F1 30A W/B R G/W ECU Main Relay Driver Sensor Ground 1 Side Stand Switch Power Supply After Main Relay Power Ground 2 Y/B Pi Br/W B/Y 44 39 25 23 11 L/G Ignition Key 33 Gr/Pi 1 Power Ground 1 B/Y 3 Sensor Supply 1 Pi/B Side Stand Indication O/Br 38
7-43 ELECTRICAL SYSTEM Radiator Fan Motor Circuit VRLA BATTERY 8Ah + R - B KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/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 Br/L O Gr/R 15A F3 R/W 15A W/B W/B IGNITION SWITCH W BR/L W/B ON OFF Br SPEEDOMETER 2 KILL SWITCH SUPPL Y GROUND L/R PIN 3 PIN 5 L/R SPEEDOMETER 1 COOLANT TEMP INPUT BATTERY W Gr/Pi PIN 8 PIN 10 HIGH COOLANT INDI O/P PIN 11 G/W W O/Gr GR/Y O Br/W G/B RADIATOR FAN RELAY RADIATOR FAN MOTOR GR/Y B/Y R B COOLANT TEMP SENSOR Y/B Y/W F8 O/Gr 7.5A Br/L W W/B GROUND PIN 20 L/R L/R KILL SWITCH PIN 19 Y/W Pi/R HIGH COOLANT INDI I/P PIN 2 IGNITION SUPPLY PIN 1 Br Br Gr/Pi O/Gr F6 15A W/B Br Location on starter relay F1 30A W/B R G/W G/W G/W ECU Main Relay Driver Engine Temp Sensor I/P Sensor Ground 1 Ignition Keys Power Supply After Main Relay Power Ground 2 Y/B Gr/Pi Br/W B/Y 44 33 25 23 11 L/G Y/W 19 Coolant Temp I/P 10 Pi/R Radiator Fan Relay G/B 14 Power Ground 1 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 O/Gr IGNITION SWITCH BR/L W/B VRLA BATTERY 8Ah + R - B FLASHER O Br B/Y SIDE INDICATOR SWITCH (CONTROL SWITCH LH) G O Gr L OFF R G O Gr F6 15A W/B Br Br/L O Br B/Y W ON OFF Br DIR IND FRONT LH B/Y Gr Gr B/Y DIR IND FRONT RH G B/Y G B/Y DIR IND REAR LH B/Y Gr B/Y Gr DIR IND REAR RH Location on starter relay F1 30 A R W/B SPEEDOMETER 1 LH INDICATOR INPUT KILL SWITCH W Gr G Gr/Pi G/W PIN 17 PIN 19 GROUND PIN 20 RH INDICATOR INPUT PIN 16 BATTERY PIN 10 W Gr G O/Gr G/W
7-45 ELECTRICAL SYSTEM Fuel Meter Circuit SPEEDOMETER 1 BATTERY W/Y W Gr/Pi G/W PIN 10 FUEL LEVEL INPUT PIN 7 W/Y W O/Gr G/W KILL SWITCH PIN 19 GROUND PIN 20 FUSE O/P FUSE I/P VRLA BATTERY 8Ah + R - B IGNITION SWITCH BR/L W/B Br G/R FUEL PUMP Pi/R W/Y G/W F2 7.5A W/B W MAIN FUSE BOX W ON OFF F8 O/Gr 7.5A Br/L Location on starter relay F1 30 A R W/B
7-46 ELECTRICAL SYSTEM Fuel Injector Circuit FUEL INJECTOR B/W Br/W B/Y W/R B/Y W/R CRANK ANGLE SENSOR IGNITION SWITCH W BR/L W/B ON OFF Br ECU Power Ground 1 Main Relay Driver Fuel Pump Relay Sensor Ground 1 Ignition Keys Sensor Supply 2 Power Supply After Main Relay Power Ground Y/B Gr/Pi R/L Br/W B/Y 44 33 27 25 23 1 11 12 B/Y L/G W/L MAIN FUSE BOX F4 F7 7.5A FUSE O/P FUSE I/P Br/L O/W Gr/R 15A F3 R/W 15A Br/L W/B KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/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 Location on starter relay F1 30A W/B R Roll Over Sensor 16 Br/G Crankshaft Input (-) B/Y 26 Crankshaft Input (+) 4 W/R Injector Driver 5 B/W TPS Y/B G/Y R/L Throttle Position Sensor 18 G/Y
7-47 ELECTRICAL SYSTEM EVAP Purge Valve Circuit BR/L W/B VRLA BATTERY 8Ah + R - B TPS Y/B G/Y R/L KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R Br/W R/W R/W L/G MAIN RELAY FUSE O/P F3 R/W 15A W/B COOLANT TEMP SENSOR Y/B Y/W ECU Power Ground 1 Main Relay Driver Throttle Position Sensor Engine Temp Sensor I/P Sensor Ground 1 Canister Purge Valve Ignition Keys Sensor Supply 2 Power Supply After Main Relay Power Ground 2 Y/B G/Pi Gr/Pi R/L Br/W B/Y 44 34 33 27 25 23 1 4 11 18 19 B/Y L/G G/Y Y/W G/Pi Br/W Location on starter relay F1 30A W/B R B/Y W/R B/Y W/R CRANK ANGLE SENSOR Crankshaft Input (-) B/Y 26 Crankshaft Input (+) W/R IGNITION SWITCH W ON OFF Br MAIN FUSE BOX F7 7.5A FUSE I/P Gr/R Br/L PURGE VALVE
7-48 ELECTRICAL SYSTEM MIL Indication Circuit KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R VRLA BATTERY 8Ah + R - B ECU Ignition Keys Power Supply After Main Relay Power Ground 2 Gr/Pi Br/W B/Y 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 F6 15A F3 R/W 15A W/B 8 11 MIL Main Relay Driver Br/R L/G F7 7.5A FUSE O/P FUSE I/P Gr/R Br/L Br/L Br Location on Starter Relay F1 30A R W/B Power Ground 1 1 B/Y CAN INTERFACE B/Y Gr/G G/L Y/L F8 O/Gr 7.5A Br/L Can Low Y/L 36 Can High G/L 37 SPEEDOMETER 2 KILL SWITCH SUPPL Y Br Gr/Pi G/W Br/R PIN 3 MIL INDICATION PIN 10 IGNITION SUPPLY PIN 1 Br O/Gr G/W Br/R GROUND PIN 5 F9 Gr/G 7.5A Br/L
7-49 ELECTRICAL SYSTEM Low Oil Pressure Indication Circuit KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R Br/W R/W R/W L/G MAIN RELAY OIL PRESSURE SENSOR Br/Pi VRLA BATTERY 8Ah + R - MAIN B FUSE BOX FUSE O/P FUSE I/P F2 7.5A O/W Br/L IGNITION SWITCH W BR/L W/B ON OFF Br F4 15A W/B W H.T. COIL 1 B/Y B O/W H.T. COIL 2 B/Y O/W B/R ECU Power Ground 1 Ignition Driver 2 Engine Speed O/P Main Relay Driver Ignition Keys Power Supply After Main Relay Ignition Driver 1 Power Ground 2 Gr/Pi Br/W B B/Y 33 25 24 23 1 2 7 11 B/Y B/R B/V L/G Location on Starter Relay F1 30A R W/B R/W W/B F3 15A Gr/R Br/L F7 7.5A Crankshaft Input (+) 4 W/R Crankshaft Input (-) B/Y 26 B/Y W/R B/Y W/R CRANK ANGLE SENSOR O/Gr Br/L F8 7.5A SPEEDOMETER 1 KILL SWITCH W Br/Pi Gr/Pi G/W PIN 19 GROUND PIN 20 OIL PRESSURE SWITCH I/P PIN 14 BATTERY PIN 10 W Br/Pi O/Gr G/W B ENGINE RPM I/P PIN 12 B/V
7-50 ELECTRICAL SYSTEM Engine RPM Indicationv Circuit VRLA BATTERY 8Ah + R - B IGNITION SWITCH W BR/L W/B ON OFF Br H.T. COIL 2 B/Y O/W B/R B/Y W/R B/Y W/R CRANK ANGLE SENSOR H.T. COIL 1 B/Y B O/W KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R ECU Ignition Driver 2 Crankshaft Input (+) Engine Speed I/P Main Relay Driver Ignition Keys Crankshaft Input (-) Power SupplyAfter MainRelay Ignition Driver Power Ground 2 Gr/Pi B/Y Br/W B B/Y 33 26 25 24 23 2 4 7 11 B/R W/R B/V L/G MAIN FUSE BOX F4 F7 7.5A FUSE O/P FUSE I/P Br/L O/W Gr/R 15A F3 R/W 15A Br/W R/W R/W L/G MAIN RELAY Br/L W/B SPEEDOMETER 1 KILL SWITCH W B Gr/Pi G/W PIN 19 GROUND PIN 20 ENGINE RPM I/P PIN 12 W B/V O/Gr G/W BATTERY PIN 10 F2 30A W/B W F8 O/Gr 7.5A Br/L Location on starter relay F1 30A W/B R Power Ground 1 1
7-51 ELECTRICAL SYSTEM ABS Circuit W W/B MAIN FUSE BOX FUSE O/P FUSE I/P F2 7.5A WHEEL SPEED SENSOR FRONT L/Pi W/R B W WHEEL SPEED SENSOR REAR R/W L/O W B W L/W PIN 10 PIN 15 PIN 20 G/W BR/L W/B G/W PIN 5 PIN 9 B/W G/W B/W W L/W G/W VRLA BATTERY 8Ah + R - B PUMP MOTOR VEHICLE SPEED INPUT IGNITION SWITCH SUPPLY FRONT WHEEL SPEED SENSOR SUPPL Y REAR WHEEL SPEED SENSOR SUPPL Y ECU EARTH SOLENOID VALVE ABS INDICATOR CAN LOW CAN HIGH FRONT WHEEL SPEED SENSOR SUPPL Y REAR WHEEL SPEED SENSOR I/P 16 15 14 11 10 9 8 7 4 3 2 1 W/R L/W Gr/G L/Pi R/W B/Y W/L B/W Y/L G/L W/R L/O B/Y W/L R ABS BOX F1 15A R W/R F2 10A CAN INTERFACE B/Y Gr/G G/L Y/L F8 O/Gr 7.5A Br/L PIN 19 Gr/Pi O/Gr PIN 3 Gr/Pi O/Gr F9 Gr/G 7.5A Br/L ECU Main Relay Driver 11 L/G Ignition Keys Gr/Pi 33 Power Ground 1 1 B/Y Power Supply After Main Relay Br/W 25 Location on starter relay F1 30A W/B R KILL SWITCH (CONTROL SWITCH RH) Gr/R Br/L ON OFF Gr/Pi Gr/R F7 Gr/R 7.5A Br/L SPEEDOMETER 1 BATTERY SPEED PULSES INPUT GROUND IGNITION SWITCH W ON OFF Br SPEEDOMETER 2 GROUND ABS INDICATION ABS ABS EARTH KILL SWITCH KILL SWITCH SUPPL Y Can High G/L 37 Can Low Y/L 36 W/B F3 R/W 15A Br/W R/W R/W L/G MAIN RELAY Power Ground 2 23 B/Y Vehicle Speed Sensor 22 L/W
7-52 ELECTRICAL SYSTEM B/Y W/R B/Y W/R CRANK ANGLE SENSOR Br/WR/W R/WL/G MAIN RELAY IGNITION SUPPLY Br Gr/Pi PIN 1 KILL SWITCH SUPPLY PIN 3 Br O/Gr G/W GROUND PIN 5 G/W VRLA BATTERY 8Ah + R - B BR/L W/B MAIN FUSE BOX F7 7.5A FUSE O/P FUSE I/P Gr/R Br/L KILL SWITCH Gr/Pi G/W PIN 19 GROUND PIN 20 O/Gr G/W HEAD LAMP ASSEMBLY B/V F6 15A Br/L Br F8 7.5A Br/L O/Gr Gr/Pi R R/B R/Y L/B B/Y Br ECU Ignition Keys Power Ground 2 Gr/Pi B/Y 33 23 HI / LO SWITCH LO HI LED Br Br/W PASS SWITCH CONTROL SWITCH LH CONTROL SWITCH RH Gr/R Br/L ON OFF Gr/Pi Gr/R B/Y KILL SWITCH LIGHT SWITCHON PO LED CONTROL Y/L Br Y/L Br Br/W NUMBER PLATE LAMP Br B/Y B/Y R B/Y Br 7 Engine Speed O/P HIGH BEAM PIN 4 R R B/V ENGINE RPM I/P PIN 12 BATTERY PIN 10 W B W B/V Power Supply After Main Relay 25 11 Main Relay Driver L/G Br/W F3 R/W 15A W/B B/G L/B R/B Y/L R/Y B/G I/P O/P 4 Crankshaft Input (+) W/R Location on starter relay F1 30A W/B R Br/W B/Y B/G SPEEDOMETER 2 SPEEDOMETER 1 IGNITION SWITCH W ONOFF Br IGNITION SWITCH ENGINE RPM B/Y Br B/V GND R/B R/Y R HIGH BEAM INDICATION KILL SWITCH INPUT Gr/Pi V Br B/Y TAIL LAMP HB LB PASS F2 7.5A W W/B Crankshaft Input (-) 26 B/Y 1 Power Ground 1 B/Y Lighting Circuit
Chapter 8 Appendix Table of Contents Additional Considerations for Racing .................. 8-2 8 Troubleshooting Guide ........................................ 8-5 Nut, Bolt and Fastener Tightness ........................ 8-9 General Lubrication ............................................. 8-10 Unit Conversion Table ......................................... 8-11
8-2 APPENDIX Additional Considerations for Racing This motorcycle has been manufactured for use in a reasonable and prudent manner and as a vehicle only. However, some may wish to subject this motorcycle to abnormal operation, such as would be experienced under racing conditions. Modenas strongly recommends that all riders side safely and obey all laws and regulations concerning their motorcycle and its operation. Racing should be done under supervised conditions and recognised sanctioning bodies should be contacted for further details. For those who desire to participate in competitive racing or related use, the following technical information may prove useful. However, please note the following important points ; You are entirely responsible for the use of motorcycle under abnormal conditions such as racing and MODENAS shall not be liable for any damages that might arise from such use. MODENAS Motorcycle Warranty specifically excludes motorcycle which are used in competitive or related uses. Please read the warranty carefully. Motorcycle racing is a very sophisticated sport, subject to many variables. The following information is theoretical only and Modenas shall not be liable for any damages that might arise from alterations utilizing this information. When the motorcycle is operated on public roads, it must be in its original state in order to ensure safety and compliance with appliance regulations. Spark Plug The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be used and the spark plug must be kept clean and the gap adjusted. Tests have shown the plug listed in the “General Information” chapter to be the best plug for general use. Since spark plug requirements change with the ignition and carburation adjustments and with riding conditions, whether or not a spark plug of the correct heat range is used should be determined by removing and inspecting the plug. Terminal [A] Insulator [B] Cement [C] Gasket [D] Centre Electrode [E] Gap [F] Reach [G] Side Electrode [H] When a plug of the correct heat range is being used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself. This temperature is about 400 ~ 800°C (750 ~ 1,450°F) and can be judged by noting the condition and colour of the ceramic insulator around the centre electrode. If the ceramic is clean and of a light brown colour, the plug is operating at the right temperature. A spark plug for higher operating temperature is used for racing. Such a plug is designed for better cooling efficiency so that it will not overheat and thus is often called a ‘colder’ plug. If a spark plug with too high a heat range is used - that is a ‘cold’ plug that cools itself too well - the plug will stay too cool to burn off the carbon and the carbon will be collected on the electrodes and the ceramic insulator.
The carbon on the electrodes conducts electricity and can short the centre electrode to ground by either coating the ceramic insulator or bridging across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause pre-ignition and knocking, which may eventually burn a hole in the top of the piston. 8-3 APPENDIX Additional Considerations For Racing Remove the spark plug and inspect the ceramic insulator. Spark Plug Inspection Whether or not the right temperature plug is being used can be ascertained by noting the condition of the ceramic insulator around the electrode. A light brown colour indicates the correct plug is being used. If the ceramic is black, it indicates that the plug is firing at too low a temperature, so the next hotter type should be used instead. If the ceramic is white, the plug is operating at too high a temperature and it should be replaced with the next colder type. CAUTION If the spark plug is replaced with a type other than the standard plug, make certain the replacement plug has the same thread pitch and reach (length of threaded portion) and the same insulator type (regular type or projected type) as the standard plug. If the plug reach is too short, carbon will build up on the plug hole threads in the cylinder head, causing overheating and making it very difficult to insert the correct spark plug later. If the plug reach is too long, carbon will build up on the exposed spark plug threads causing overheating, pre ignition and possibly burning a hole in the piston top. In addition, it may be impossible to remove the plug without damaging the cylinder head. Spark Plug Condition Normal Operation Oil Fouling Carbon Fouling Overheating
8-4 APPENDIX Additional Considerations For Racing NOTE The heat range of the spark plug functions like a thermostat for the engine. Using the wrong type of spark plug can make the engine run too hot (resulting in engine damage) or too cold (with poor performance, misfiring and stalling).The standard plug has been selected to match the normal usage of motorcycle is combined street and highway riding. Unsual riding conditions may require a different spark plug heat range. For racing, install the colder plug.
8-5 APPENDIX Troubleshooting Guide NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the common difficulties. Engine Doesn’t Start, Starting Difficulty; Starter motor not rotating Starter motor defective Battery voltage low Relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch defective Engine stop switch defective Engine stop switch off Fuse blown Starter motor rotating but engine doesn't turn over Starter motor clutch defective Engine won’t turn over Valve seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Camshaft seizure Transmission gear or crankcase bearing seizure Kickstarter return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Sticking of the valve in the fuel tap Fuel tap vacuum hose clogged Fuel tap air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open Starting technique faulty (when flooded, crank the engine with the throttle fully opened to allow more air to reach the engine) No spark, spark weak Ignition switch not on Engine stop switch turned off Spark plug dirty, damaged or maladjusted Spark plug cap or high tension wiring damaged Spark plug cap shorted or not in good contact Ignition coil damaged Exciter coil damaged ECU unit broken Flywheel magneto damaged Ignition or engine stop switch shorted Wiring shorted or open Fuel / air mixture incorrect Idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed or missing Air cleaner duct loose Compression low Cylinder, piston worn Piston ring bad (worn, weak, broken or sticking) Piston ring / land clearance excessive Cylinder head gasket Cylinder head not sufficiently tightened down Cylinder head warped Spark plug loose No valve clearance Valve spring broken or weak Valve not seating properly (valve bent, worn or carbon accumulation on the seating surface) Poor Running at Low Speed; Spark weak Spark plug dirty, damaged or maladjusted Spark plug cap or high tension wiring damaged Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble Ignition coil damaged ECU unit broken Flywheel magneto damaged Fuel / air mixture incorrect Idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed or missing Air cleaner duct loose Choke valve closed Float level too high or too low Fuel tank air vent obstructed Throttle body holder loose Compression low Cylinder, Piston worn Piston rings bad ( worn, weak, broken or sticking ) Piston ring / land clearance excessive Cylinder head gasket Cylinder head not sufficiently tightened down Cylinder head warped No valve clearance Spark plug loose Valve spring broken or weak Valve not seating properly (Valve bent, worn or carbon accumulation on the seating surface)
8-6 APPENDIX Troubleshooting Guide Crankshaft oil seal deteriorated or damaged Reed valve damaged Other Throttle valve doesn’t slide smoothly Engine oil viscosity too high Brake dragging Poor Running, No Power at High Speed; Firing incorrect Spark plug dirty, damaged or maladjusted Spark plug cap or high tension wiring damaged Spark plug cap shorted or not in good contract Spark plug incorrect Ignition coil trouble Pickup coil trouble Exciter coil shorted or open ECU unit trouble Fuel/air mixture incorrect Fuel level too high or too low Air passage clogged Air cleaner clogged, poorly sealed or missing Air cleaner duct poorly sealed Throttle body holder loose Fuel to carburetor insufficient Water or foreign matter in fuel Fuel tank air vent obstructed Fuel line clogged Fuel tap clogged Air cleaner duct loose Compression low Cylinder, piston worn Piston rings bad (worn, weak, broken or sticking) Piston ring / land clearance excessive Cylinder head gasket Cylinder head not sufficiently tightened down Cylinder head warped No valve clearance Spark plug loose Valve not seating properly (Valve bent, worn or carbon accumulation on the seating surface) Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Miscellaneous Float level too high or too low Throttle valve does not fully open Air cleaner clogged Overheating Engine oil level too high Engine oil viscosity too high Crankshaft bearing worn or damaged Water or foreign matter in fuel Brake dragging Clutch slipping Overheating; Firing incorrect Spark plug dirty, broken or maladjusted Spark plug incorrect ECU unit trouble Fuel / air mixture incorrect Fuel level too low Throttle body holder loose Air cleaner clogged Air cleaner poorly sealed or missing Air cleaner duct loose Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Brakes dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Clutch Operation Faulty; Clutch slipping No clutch release play Friction plate worn or warped Steel plate worn or warped Clutch spring or weak Clutch release maladjusted Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch release play excessive Clutch plate warped or too rough Clutch spring tension uneven Engine oil deteriorated Engine oil level too high Engine oil viscosity too high Clutch housing frozen on drive shaft Clutch release mechanism trouble
8-7 APPENDIX Troubleshooting Guide Gear stuck on the shaft Shift return spring weak or broken Shift pawl spring broken Shift return spring pin loose Gear set level binding on pivot bolt External shift mechanical arm worn Shift drum damaged Jumps out of gear Shift fork worn Gear groove worn Gear dogs, holes, and or recesses worn Shift drum groove worn Shift drum set lever spring weak or broken Shift fork guide pin worn Shift pawl spring weak or broken Drive shaft, output shaft and or gear splines worn Overshifts Shift drum set lever spring weak or broken Shift pawl spring weak or broken Abnormal Engine Noise; Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Overheating Spark plug incorrect Piston slap Cylinder / piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston holes worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft journals worn Other noise Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring worn, broken or stuck Piston seizure or damaged Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Camshaft chain tensioner trouble Camshaft chain, sprocket, guides worn Loose magneto flywheel Abnormal Drive Train Noise; Clutch noise Clutch housing or hub damaged Drive chain noise Drive chain adjusted improperly Chain worn Rear and or engine sprocket(s) worn Chain lubrication insufficient Rear wheel misalign Abnormal Frame Noise; Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorberdamaged Brake noise Brake pad over worn or worn unevenly Disc worn unevenly or scored Exhaust Smoke Excessively; White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Choke valve closed Float level too high Brown Smoke Fuel level too low Air cleaner duct loose Air cleaner poorly sealed or missing Clutch housing / friction plate clearance excessive Clutch housing gear / primary gear backlash excessive Transmission noise Crankcase bearing worn Metal chip jammed in gear teeth Transmission gears worn or chipped Engine oil insufficient or too thin Kick ratchet gear not properly disengaging from kick gear Kick idle gear worn or chipped Other Noise Bracket, nut bolt etc. not properly mounted or tightened
8-8 APPENDIX Troubleshooting Guide Handling and or Stability Unsatisfactory; Handlebar hard to turn Steering stem locknut too tight Steering stem bearing damaged Race(s) dented or worn Steering stem lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swing arm bushing damaged Rim warped Spokes loose Front, rear axle runout excessive Wheel bearing worn Handlebar clamp bolt loose Steering stem head bolt and or handlebar bracket bolt loose Handlebar pulls to one side Frame bent Wheel misalignment Swing arm bent or twisted Swing arm pivot shaft runout excessive Steering stem bent Front fork leg bent Right/left front fork oil level uneven Rear shock absorber and or swing arm bent Shock absorption unsatisfactory (Too hard) Front fork oil excessive Front fork oil viscosity too high Front fork bent Front fork bent Tire air pressure too high (Too soft) Front fork oil insufficient and/or leaking Front fork oil viscosity too low Front fork, rear shock absorber spring(s) weak Front fork oil leaking Rear shock absorber oil leaking Tire air pressure too low Battery Discharged; Battery faulty (e.g. plates sulphated, shorted through sedimentation, electrolyte level too low) Battery lead making poor contact Regulator / rectifier trouble Ignition switch damaged Load excessive (e.g. bulb of excessive watt age) Flywheel magneto damaged Stator coil open or short Wiring faulty Battery Overcharged; Regulator / Rectifier trouble Battery trouble Brakes Don’t Hold Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder
8-9 APPENDIX Nut, Bolt and Fastener Tightness NOTE For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). Tightness Inspection • Check the tightness of bolts and nuts listed here. • Also check to see that each cotter pin is in place and in good condition. If there are loose fasteners, re-torque them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by ½ turn, then tighten it. If cotter pins are damaged, replace them with new ones. • Final Drive : Chain Adjuster Locknuts Rear Sprocket Nuts Nut, Bolt And Fastener To Be Checked • Wheels : Spoke Nipples Front Axle Nut CotterPin Front Axle Nut Rear Axle Nut CotterPin Rear Axle Nut • Brake : Front Brake Adjust Nut Rear Brake Adjust Nut Brake Lever Pivot Nut Brake Rod Joint Cotter Pin • Suspension : Front Fork Clamp Bolts Swing Arm Pivot Shaft Nut Rear Shock Absorber Mounting Bolts and Nuts • Steering : Chain Adjuster Locknuts Handlebar Clamp Bolts • Engine : Engine Mounting Bolts, Nuts Cylinder Head Bolts and Nuts Shift Pedal Bolts Exhaust Pipe Holder Nuts Muffler Bolt and Nut • Other : Side Stand Nut Foot peg Mounting Bolts Center Stand Cotter Pin