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Page 18-1



Headlight12V 60W/55WH4 / HB2 / 9003
Brake/taillight12V 32/3 cp (27/8 W) x21157
Turn signal lightsFront12V 32/3 cp (23/8 W) x2 1157
Rear12 V 32 cp (23 W) 1156
License light12V 4cp
Indicator lightsTurn signal12V 3W34908-KM1-671
Neutral12V 3W34908-KM1-671
High beam12V 3W34908-KM1-671
Meter light12v 3.4W x1, 1.7W x234908-MG9-951 or 34908-MN8-700
Main Fuse30A
(fan, ignition, headlight, oil/neutral, brake/turn/horn, parking)
10A x6, 15A x1 (brake/turn/horn)
Fuel pump flow capacity/min600cc (0.630 US qt, 0.528 Imp qt)


Radiator thermostatic switch18 N.m (1.8 kg-m, 13 ft-lb) -- Apply sealant to threads
Oil Pressure Switch12 N.m (1.2 kg-m, 9 ft-lb)-- Apply sealant to threads
Ignition switch mounting bolt25 N.m (2.5 kg-m, 18 ft-lb)

Page 18-7


The cooling fan motor is actuated by the thermostatic switch located in the bottom of the radiator.

If the fan motor does not start, disconnect the Black/Blue lead from the thermostatic switch and ground it with a jumper wire as shown.
Turn the ignition switch ON. The cooling fan motor should start running. If it does not start, check for battery voltage from the Black/Blue lead of the fan motor connector and ground with ignition switch ON.
If there is no voltage, check for a blown fuse, loose terminals or connectors, or an open circuit.
If there is voltage, inspect the thermostatic switch as follows: Remove the switch.
Connect one lead of an ohmmeter to the connector of the thermostatic switch and the other to the body.

Suspend the thermostatic switch in a pan of coolant (50-50 mixture) and check the temperatures at which the switch opens and closes.
Make sure that there is no continuity at room temperature and then gradually raise the coolant temperature. The switch should show continuity (close) at 93°-97°C (199°-207° F).


Install a new O-ring on the switch.
Apply sealant to the switch threads and install it.
Tighten the switch to the specified torque.

TORQUE: 18 N.m (1.8 kg-m, 13 ft-lb)



Remove the seat and fuel tank.
Disconnect the Green/Blue wire from the temperature sensor.
Check for continuity between the sensor body and ground.
There should be continuity.
If there is no continuity, check the thermostat housing for looseness and recheck. If there is still no continuity, remove. The temperature sensor from the thermostat housing.

Page 18-8

Suspend the temperature sensor in a pan of coolant over a heater and measure the resistance through the sensor as the coolant heats up.
Resistance130-180 Ohm.25-30 Ohm.



Replace the sensor if it is out of specification by more than 10% at either temperature.


Disconnect the wire from the temperature sensor and short it to ground.

Turn the ignition switch ON. The temperature gauge needle should move all the way to (H).




Remove the seat.
Check the sub-fuse (10 A).
Remove the relay from the rubber bracket and check the relay connector terminals for looseness and corrosion.

Inspect as follows:
Disconnect the connector and test the wires on the main harness side.
Between Bl (+) and body ground (-)
with the ignition switch "ON"
Battery voltage should come.
Y/Bu wire between the pump
relay and spark unit
Bl/Bu wire between the pump
relay and fuel pump

Hint: Here is a full wiring diagram of how the fuel pump is powered

Page 18-9



Turn the ignition switch OFF. Remove the seat and disconnect the fuel pump relay wire connnectors. Short the black and black/blue wire terminals with a wire jumper wire.
Disconnect the fuel tube from the T-joint near the carburetor and hold a graduated beaker under the fuel tube.


Turn the ignition switch ON and let fuel flow into the beaker for 5 seconds, then turn the ignition switch OFF.
Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute.

600 cc (0.630 US qt. 0.528 Imp qt) /minutes at 10 V


Make sure that the oil pressure warning light comes on with the ignition switch "ON".
If the light does not come on, inspect as follows:
Remove the drive sprocet cover.
Disconnect the oil pressure switch wire from the switch by removing the terminal screw. Short it to ground using a jumper wire.
Turn the ignition switch "ON".

The oil pressure warning light should come on.
If the light does not come on, check the bulb, sub-fuse (10A) and wires for a loose connection or an open circuit.
Start the engine and make sure that the light goes out. If the light does not go out, check the oil presure (page 2-4).
If the oil pressure is normal, replace the oil pressure switch. (page 2-4)



Remove the drive sprocket cover and disconnect the connector.
Check the neutral switch for continuity between the light green/red connector and body ground.
There should be continuity with the transmission in neutral and no continuity with the transmition in any gear.
If there is no continuity in neutral, remove the drive sprocket cover (page 8-2) and check the wire connection for an open circuit.

Page 18-10


Remove the seat and rear cowling (pages 13-25).
Remove the turn signal relay from the rubber bracket.

Check the turn signal circuit for proper connections before making this test.

Check each terminal as indicated below:

White/Green:D.C. 12 V Positive (+)
Green: D.C. 12 V Negative (-)
Gray:Turn signal wire of one side; connect
the other side to ground (frame).

Check the left and right turn signal operation.

If the turn signal relay fails this test, replace it.