Locate the diode on the main wiring harness

3If the switch is good, check for voltage at
one of the terminals on the clutch switch
wiring connectors with the ignition ON - there
will be voltage on one terminal and zero on
the other. If voltage is indicated, check the
other components in the starter circuit as
described in the relevant sections of this
Chapter. If no voltage is indicated, or if all
components are good, check the wiring
between the various components (see the
wiring diagrams at the end of this Chapter).

Replacement

4 Remove the clutch lever (see Chapter 6, Section 5).

5 Disconnect the wiring connectors from the clutch switch (see illustration 22.2).Using a small screwdriver, push the switch from the connector end and withdraw it from inside the bracket.

6 Installation is the reverse of removal. Make sure the ridge on the top of the switch locates in the cutout in the lever bracket, and push the switch fully home.

23 Diode -

check and replacement

Note:The diode switch is part of the safety circuit which prevents the engine from starting with the transmission in gear unless the clutch lever is pulled in and the sidestand is up, and prevents the engine from running with the sidestand down unless the transmission is in neutral.

Check

1 Remove the fuel tank (see Chapter 4).

2 The diode is a small block that plugs into the main wiring harness (see illustration).

3Disconnect the diode from the harness. If necessary remove any tape used to bind it to the harness.

4 Using an ohmmeter or continuity tester, connect one probe to one of the outer terminals of the diode and the other probe to the middle terminal of the diode and test for continuity. Now reverse the probes. The diode should only show continuity in one direction (as indicated by the symbol on the body of the

diode). If the diode shows continuity or no continuity in both directions, it should be renewed.

5 If the diode is good, repeat the test between the other outer terminal and the middle terminal. Again, the diode should only show continuity in one direction. If it doesn't it should be renewed.

6 If the diode is good, check the other components in the starter circuit as described in the relevant sections of this Chapter. If all components are good, check the wiring between the various components (see the wiring diagrams at the end of this Chapter).

Replacement

7 Follow Steps 1 to 3 and connect the new
diode to the main wiring harness. Use
insulating tape to bind it in place.

1 Generally speaking, the handlebar switches are reliable and trouble-free. Most problems, when they do occur, are caused by dirty or corroded contacts, but wear and breakage of internal parts is a possibility that should not be overlooked when tracing a fault. If breakage does occur, the entire switch and related wiring harness will have to be renewed as individual parts are not available.

2 The switches can be checked for continuity using an ohmmeter or a continuity test light. Always disconnect the battery negative (-ve) lead, which will prevent the possibility of a short circuit, before making the checks.

3 Trace the wiring from the switch in question back to its connector and disconnect it. On R, T, V, W, X and Y models the connectors are inside the headlight shell (see Section 7), on SW, SX and SY models they are inside the fairing (see Chapter 8).

4 The right-hand switch connector is the red
9-pin connector and the left-hand switch
connectors are the green 6-pin and black
4-pin connectors.

5 Check for continuity between the terminals
of the switch wiring with the switch in the
various positions (ie switch off - no continuity,

switch on - continuity) - see the wiring diagrams at the end of this Chapter.

6 If the continuity check indicates a problem exists, refer to Section 25, remove the switch and spray the switch contacts with electrical contact cleaner. If they are accessible, the contacts can be scraped clean carefully with a knife or polished with crocus cloth. If switch components are damaged or broken, it will be obvious when the switch is disassembled.

7 Clean the inside of the switch body thoroughly and smear the contacts with silicone grease before reassembly

25 Handlebar switches -

removal and installation

Removal

1 If the switch unit is to be removed from the motorcycle, rather than just displaced from the handlebar, it will be necessary to disconnect the switch wiring from the main wiring harness.

2 Trace the wiring from the switch In question back to its connector and disconnect it. On R, T, V, W, X and Y models the connectors are inside the headlight shell (see Section 7), on SW, SX and SY models they are inside the fairing (see Chapter 8).

3 The right-hand switch connector is the red
9-pin connector and the left-hand switch
connectors are the green 6-pin and black
4-pin connectors. Work back along the wiring,
freeing it from all the relevant clips and ties
and noting its correct routing.

4 In addition, the right-hand switch wiring is connected to the front brake light switch (two wires) and the left-hand switch wiring is connected to the clutch switch (two wires), horn (two wires) and turn signals (four wires).

5 Unscrew the two handlebar switch screws and free the switch from the handlebar by separating the halves (see illustrations).Note that the choke (left side) and throttle (right side) cables must be detached to fully remove the switches (see Chapter 4).

Installation

6Installation is the reverse of removal. Make

9»16 Electrical system

25.5c Unscrew the two left-hand switch screws (rear screw arrowed)...

Date: 2016-01-14; view: 520