7. Connect a jumper wire between pins No. 2 and No. 6.
Troubleshooting
The left front and rear turn signal lights should illuminate.
2
The following troubleshooting procedures help isolate
8. Connect a jumper wire between pins No. 4 and No. 8
specific problems to the module. If it is necessary to access
and depress the right turn signal switch button. The right
the turn signal module, remove it as described in Chapter
front and rear turn signal lights should illuminate.
Twelve.
9. Connect a jumper wire betweens pins No. 6 and No. 10
Refer to Figure 98 or Figure 99 for socket and module
and depress the left turn signal switch button. The left front
pin connector identification.
and rear turn signal lights should illuminate.
10. Remove the jumper wire and turn the ignition switch
off.
One or both turn signals do not flash. Light on front or
rear side is lit, but does not flash
11. If the module passed all six tests, the module is service-
able. If the module failed one or more tests, refer to Trou-
1. Remove the lens and check for a burned out bulb. Re-
bleshooting in this section.
place bulb if necessary.
2. If the bulb is good, check for the following:
Performance Test
a. Check the bulb socket contacts for corrosion. Clean
(1994-1996 Models)
contacts and recheck. If corrosion consistently builds
on the contacts, wipe the contacts with a dielectric
If the turn signals are not working properly, perform the
grease before installing the bulb.
following performance test. A jumper wire, ohmmeter and
b. Check for a broken bulb wire. Repair the wire or con-
voltmeter will be required.
nector.
c. Check for a loose bulb socket where it is staked to the
1. Remove the turn signal module as described in Chapter
housing. If the bulb socket is loose, replace the light
Twelve.
assembly.
2. After removing the module, identify the socket connec-
d. Check for a poor ground connection. If the ground is
tor and module pin connectors using the diagram in Figure
poor, scrape the ground mounting area or replace
99.
damaged ground wire(s), as required.
3. With ignition switch off, check for ground at pin No. 1.
4. Turn the ignition switch on.
Turn signals do not operate on one side
5. Check for voltage at pin No. 2. Voltmeter should read 12
volts.
1. Perform the checks listed under One or both turns sig-
6. Connect a jumper wire between pins No. 2 and No. 4.
nals do not flash. Light on front or rear side is lit, but does
The right front and rear turn signal lights should illuminate.
not flash in this section. If these checks do not locate the
7. Connect a jumper wire between pins No. 2 and No. 5.
problem, proceed to Step 2.
The left front and rear turn signal lights should illuminate.
2. Inoperative handlebar directional switch. Perform the
following:
CAUTION
a. Turn the ignition switch on.
Do not use a jumper on 1996 models in Steps
b. Disconnect the turn signal module electrical connec-
8 or 9. The turn signal switch will be dam-
tor.
aged.
c. Locate pin No. 8 or No. 10 (1991-1993 models) or
pin No. 6 or No. 7 (1994-1996 models ) on the socket
8A. On 1994-1995 models, connect a jumper wire between
connector.
pins No. 4 and No. 6 and depress the right turn signal switch
d. With a voltmeter set on the DC scale, connect the
button. The right turn signal lights should illuminate.
negative lead to a good ground and the positive lead
8B. On 1996 models, depress the right turn signal button
to one of the pin numbers specified in substep c and
and check for 12 volts at pin No. 6.
press the turn signal switch. The voltmeter should
9A. On 1994-1995 models, connect a jumper wire between
read 12 volts when the switch is pressed in.
pins No. 5 and No. 7 and depress the left turn signal switch
e. If there is a 12 volt reading, proceed to Step 3.
button. The Left turn signal lights should illuminate.
f. If there is no voltage reading, proceed to Step 4.
9B. On 1996 models, depress the left turn signal button and
3. If 12 volts were recorded in Step 2, and the lights and
check for 12 VDC at pin No. 7.
connecting wires are in good condition, the module may be
10. Remove the jumper wire and turn the ignition switch
damaged. Replace the module and retest.
off.
4. If no voltage was recorded in Step 2, check the handle-
11. If the module passed all six tests, the module is service-
bar switch and related wiring for damage. Further tests can
able. If the module failed one or more tests, refer to Trou-
be made by performing continuity and voltage checks.
bleshooting in this section.
5. Reconnect the turn signal module electrical connector.
Turn signals/hazard lights do not operate on both sides
TURN SIGNAL MODULE
(1997-2003 MODELS)
1. If none of the turn signals or hazard flashers operate,
Use the following troubleshooting charts
(Figures
check the turn signal module for proper ground with an
100-103) to help isolate specific turn signal problems. Find
ohmmeter. Using the wiring diagram at the end of this man-
the particular symptom and follow the procedures until the
ual, trace the ground connection from the module to the
problem is corrected. If it is necessary to access the turn sig-
frame tab. If a ground is not present, remove the ground
nal module, remove it as described in Chapter Twelve.
wire at the frame and scrape the frame and clean the con-
The troubleshooting charts refer to various connectors by
nector. Check the ground wire for breaks. Repair as re-
code numbers. The connectors are identified in the wiring
quired. If a ground is present, perform Step 2.
diagrams located at the end of this manual.
Refer to Figure 104 to identify the socket and pin con-
CAUTION
nectors in the turn signal module connector.
Do not operate the module without pin No. 1
grounded. Otherwise, the module will burn
out.
EXCESSIVE VIBRATION
2. Refer to the appropriate wiring diagram and locate the
Excessive vibration is usually caused by loose engine
accessory circuit breaker. Turn the ignition switch on and
mounting hardware. High speed vibration may be due to a
check for voltage on the hot or load side of the circuit
bent axle shaft or loose or faulty suspension components.
breaker with a voltmeter. If there is no voltage, refer to
Vibration can also be caused by the following conditions:
Chapter Twelve and check the following components:
1. Improperly balanced wheel(s).
2. Defective or damaged tire(s).
a. Accessory circuit breaker.
3. Defective or damaged wheel(s).
b. Main circuit breaker.
4. Tight primary chain links.
c. Starter relay.
5. Severely worn primary chain.
d. Ignition switch.
6. Loose or damaged engine mounting bracket.
7. Internal engine wear or damage.
e. Circuit wiring.
8. Broken frame.
Turn signals do not cancel
FRONT SUSPENSION AND STEERING
Poor handling may be caused by improper tire pressure, a
1. Support the motorcycle so that the front wheel clears the
damaged or bent frame or front steering components, worn
ground.
wheel bearings or dragging brakes.
2A. On 1994 models, connect an ohmmeter to the speed-
ometer white/green wire and ground. Spin the front wheel
and watch the ohmmeter scale. The ohmmeter should alter-
Irregular or Wobbly Steering
nate between 0 ohms and infinity.
1. Loose wheel axle nut(s).
a. If ohmmeter reading is correct, disconnect the mod-
2. Loose or worn steering head bearings.
ule pin connector. With a voltmeter set on the DC
3. Excessive wheel hub bearing play.
scale, connect the negative lead to a good ground and
4. Damaged cast wheel.
the positive lead to the No. 3 pin (white/green) socket
5. Spoke wheel out of alignment.
connector. The voltmeter should read 12 volts. If ohm
6. Unbalanced wheel assembly.
and volt readings are correct, the module is damaged.
7. Worn hub bearings.
b. If ohmmeter reading is incorrect, check for damaged
8. Incorrect wheel alignment.
wiring from the speedometer white/green wire to the
9. Bent or damaged steering stem or frame (at steering
module. If wiring is okay, the reed switch in the
neck).
speedometer may be damaged.
10. Tire incorrectly seated on rim.
11. Excessive front end loading from non-standard
2B. On 1995-1996 models, set a voltmeter to the DC scale.
equipment.
Connect the positive meter lead to pin 3 and connect the
negative meter lead to a good ground. Turn the ignition on
and spin the rear wheel. The voltmeter readings should al-
Stiff Steering
ternate between 0-1 volts and 8-12 volts. If the voltage is
within specification, replace the turn signal module. If the
1. Low front tire air pressure.
readings are not within specification, check the speedome-
2. Bent or damaged steering stem or frame at the steering
ter wiring and the speedometer.
neck.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
100
TURN SIGNALS WILL NOT CANCEL
(1997-1998 MODELS, EXCEPT LATE-MODEL 1998 833 MODELS)*
Turn the ignition on. Check for voltage on the white/green terminal on the harness side of the turn
signal module connector [30] while it is still connected to the turn signal module. The voltage should
fluctuate between 0-1 volts and 6-12 volts while the rear wheel is being turned. Does it?
Yes
No voltage
No fluctuation
Replace the turn
Disconnect the turn signal module
Check for continuity between
signal module.
connector [30] and remove the
the white/green speedometer
white/green speedometer harness
harness wire on the back of
wire from the back of thespeedom-
the speedometer and
eter. Check for continuity to
white/green wire in the turn
ground on the white/green wire. Is
signal module connector [30].
there continuity present?
Is there continuity present?
Yes
No
Yes
No
Repair
Replace the
Is battery
Repair open
short to
turn signal
voltage pres-
in white/green
ground on
module.
ent on
wire.
white/green
white/green
wire.
wire with the
connector
[30] still dis-
connected?
Yes
No
Repair the short
Refer to speedome-
to voltage.
ter troubleshooting.
*Late model 1998 883 models are equipped with a speedometer
featuring self-diagnostic capabilities.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
101
TURN SIGNALS WILL NOT CANCEL
(LATE MODEL 1998 883CC AND 1999-2003 MODELS)
Use this chart for speedometer trouble
codes 9 (speed output shorted high) and 10
(speed output shorted low or open).
Turn the ignition on. Check for voltage on the white/green terminal on the harness
side of the turn signal module connector [30] while it is still connected to the turn sig-
nal module. The meter should read 3-6 volts when the wheel is turned faster than 3
mph, and it should read 9-11 volts when the wheel is stationary. Does it?
Yes
No voltage
No fluctuation
Disconnect connector [30] and re-
move the speedometer harness con-
Replace the turn
Disconnect connector [30] and
nector at the back of the
signal module.
remove the speedometer har-
speedometer. Check for continuity be-
ness connector at the back of
tween the white/green speedometer
the speedometer. Check for con-
harness connector at the back of the
tinuity to ground on the
speedometer and white/green wire in
white/green wire. Is there conti-
the turn signal module connector [30].
nuity?
Is there continuity?
Yes
No
Yes
No
Is battery
Repair
Replace the
voltage pres-
Repair open in
short to
turn signal
ent on
white/green
ground on
module.
white/green
wire.
white/green
wire with the
wire.
connector
[30] still dis-
connected?
Yes
No
Repair the short
Refer to speedome-
to voltage.
ter troubleshooting.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
102
TURN SIGNALS WILL NOT FLASH RIGHT, WILL NOT FLASH LEFT
2
(1997-2003 MODELS, EXCEPT LATE-MODEL 1998 883 MODELS)
Does the turn signal indicator illumi-
Perform the diagnostic proce-
nate on the side that will not flash?
No
dure in Figure 103.
Yes
Inspect the bulbs on the side that will
Replace the bulbs as necessary.
not flash. Have the bulbs failed?
Yes
No
Disconnect the turn signal module
connector [30] from the turn signal
With the bulbs removed, check
module. Place a jumper wire across
for continuity between the termi-
No
terminals 2 and 3 in the connector,
nal in the bulb socket and
and turn the ignition on. Both right
terminal 3. Is there continuity?
side turn signal lamps should be on.
Are they?
Yes
Yes
No
Disconnect the turn signal module
connector [30] from the turn signal
Repair the
Repair the
module. Place a jumper wire across
open ground
open in the
terminals 2 and 4 in the connector,
circuit.
wire.
and turn the ignition on. Both left
side turn signal lamps should be on.
Are they?
Yes
No
Replace
With the bulbs re-
Repair the
No
the turn
moved, check for
open in the
signal
continuity between
wire.
module.
terminal in the bulb
socket and terminal
Repair the
4. Is there continuity?
Yes
open
ground
circuit.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
103
TURN SIGNALS WILL NOT FLASH, 4-WAY FLASHES INOPERABLE
Inspect the bulbs on a side that will
Replace the bulbs as necessary.
not flash. Has a bulb failed?
Yes
No
Disconnect the turn signal module
Keep the ignition on. Measure the volt-
connector [30] Turn the ignition on.
age between terminals 1 and 7 of the
Measure the voltage between termi-
turn signal module connector when the
Yes
nals 1 and 2 on the connector. Does
right turn signal switch is pressed.
the meter read 12 volts?
Does the meter read 12 volts?
No
No
Yes
Check the resistance to ground at terminal 1
of the turn signal module connector. Is the
Depress the right turn signal switch,
resistance less than 1 ohm?
and check the voltage at the
white/brown terminal in the harness
side of the right handlebar connector
Yes
No
[22] while it is connected to the con-
trols. Does the meter read 12 volts?
Check for 12 volts at
Repair poor ground
both terminals of the
connection.
Yes
No
15 amp accessory
circuit breaker. Is 12
volts present at both
Yes
Repair the open
Check for conti-
terminals?
between the han-
nuity at the or-
Repair the open in the
ange/white wire
dlebar connector
orange/white wire be-
to ground. Is
[22] and the turn
No
tween the accessory
there continuity?
signal module.
circuit breaker terminal
and turn the signal
One
Neither
module.
Yes
No
terminal
terminal
Repair the short
Is 12 volts present
Replace
Repair the
to ground.
at orange/white
the circuit
open be-
wire in connector
breaker.
tween the
[22]?
ignition
Repair the open
No
switch and
between the
the circuit
Yes
connector [22]
breaker
and the circuit
block.
breaker block.
Replace the turn
signal switch.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
Depress the left turn signal switch
Keep the ignition on. Measure the voltage be-
and check the voltage at the
tween terminals 1 and 8 of the turn signal mod-
white/violet terminal in the harness
ule connector when the left turn signal switch
No
side of the left handlebar connector
is pressed. Does the meter read 12 volts?
[24] while it is connected to the con-
trols. Does the meter read 12 volts?
Yes
Yes
No
Place a jumper across terminals 2 and 3 in the turn
signal module connector, and turn the ignition on.
Repair open between
Check continuity at the
Both right turn signal lamps should turn on. Do they?
connector [24] and
white/violet wire to ground.
turn signal module.
Is continuity present?
No
Yes
Yes
No
Check for continuity
Place a jumper
Repair the short
Is 12 volts present at the
between terminal 3
across terminals 2
to ground.
orange/white wire in
and the lamps. Is
and 4 in the turn
connector [24]?
continuity present?
signal module con-
nector, and turn the
ignition ON. Both
left turn signal
Yes
No
No
Yes
lamps should turn
on. Do they?
Repair the
Repair
Replace the turn
Repair the open
open be-
open
signal switch.
between the
tween the
ground
connector [24]
lamps and
circuit.
Yes
No
and the circuit
turn signal
breaker block.
module con-
nector [30].
Replace
Check for conti-
the turn
nuity between
signal
terminal 4 and
module.
the lamps. Is
there continuity?
Yes
No
Repair the open
Repair the open between
ground circuit.
the lamps and turn sig-
nal module connector
[30].
-------------------------------------------------------------------------------------------------------------------------------------------------------------
104
TURN SIGNAL MODULE CONNECTORS
(1994-2003 MODELS)
Socket housing alignment tabs
Pin housing alignment tabs
Speedometer
Left turn
Left turn
signal switch
signal light
Module
Right turn
Right turn
signal switch
signal light
Power
Pin
Wire
number
color
Description/function
1
Black
Module ground to motorcycle
2
Orange/white
12vdc input from accessory circuit breaker
3
White/green
Speedometer reed switch input
4
Brown
Pulsed 12 vdc for flashing right turn signal lights
5
Violet
Pulsed 12 vdc for flashing left turn signal lights
6
-
Not used
7
White/brown
12 vdc from right turn signal switch (when pressed)
8
White/violet
12 vdc from left turn signal switch (when pressed)
-------------------------------------------------------------------------------------------------------------------------------------------------------------
3. Loose or worn steering head bearings.
Insufficient Braking Power
2
Worn brake pads or disc, air in the hydraulic system,
Stiff or Heavy Fork Operation
glazed or contaminated pads, low brake fluid level, or a
leaking brake line or hose can cause this problem. Visually
1. Incorrect fork oil viscosity.
check for leaks. Check for worn brake pads. Also check for
2. Excessive amount of fork oil.
a leaking or damaged primary cup seal in the master cylin-
3. Bent fork tubes.
der. Bleed and adjust the brakes. Rebuild a leaking master
4. Incorrect fork springs.
cylinder or brake caliper. Brake drag will result in excessive
heat and brake fade. See Brake Drag in this section.
Poor Fork Operation
Spongy Brake Feel
1. Low fork oil level
2. Contaminated fork oil.
This problem is generally caused by air in the hydraulic
3. Worn or damaged fork tubes.
system. Bleed and adjust the brakes as described in Chapter
4. Bent or damaged fork tubes.
Sixteen.
5. Incorrect fork springs.
6. Heavy front end loading from non-standard equipment.
Brake Drag
Poor Rear Shock Absorber Operation
Check brake adjustment. Check for insufficient brake
pedal and/or hand lever free play. Also check for worn,
1. Rear shocks adjusted incorrectly.
loose or missing parts in the brake calipers. Check the brake
2. Incorrect loading.
disc for warp or excessive runout.
3. Heavy rear end loading from non-standard equipment.
4. Weak or worn springs.
Brakes Squeal or Chatter
5. Damper unit leaking.
6. Shock shaft worn or bent.
Check brake pad thickness and disc condition. Make sure
7. Incorrect rear shock springs.
that the pads are not loose. Check that the anti-rattle springs
are properly installed and in good condition. Clean off any
dirt on the pads. Loose components can also cause this.
BRAKE PROBLEMS
Check for:
All models are equipped with front and rear disc brakes.
1. Warped brake disc.
Perform the maintenance specified in Chapter Three to
2. Loose brake disc.
minimize brake system problems. Brake system service is
3. Loose caliper mounting bolts.
covered in Chapter Sixteen. When refilling the front and
4. Loose front axle nut.
rear master cylinders, use only DOT 5 silicone-based brake
5. Worn wheel bearings.
fluid.
6. Damaged hub.
Table 1 and Table 2 are on the following page.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
Table 1 STARTER SPECIFICATIONS
Current draw
Normal
160-200 amps
Maximum
250 amps
Maximum no-load current @ 11.5 volts
90 amps
Minimum no-load speed @ 11.5 volts
3000 rpm
Table 2 ELECTRICAL SPECIFICATIONS
Alternator
Stator coil resistance
0.2-0.4 ohms
AC voltage output
19-26 Vac per 1000 rpm
Battery capacity
12 volt, 19 amp hr.
Ignition coil
Primary resistance
1200S models
0.4-0.6 ohms
All other models
2.5-3.1 ohms
Secondary resistance
1986-1992 models
11,250-13.750 ohms
1993-2003 models
1200S models
11,700-12,700 ohms
All other models
10,000-12,500 ohms
Spark plug cable resistance (1998-2003 1200S)
Front left cable (No. 1)
5039-11,758 ohms
Rear center cable (No.2)
4665-10,886 ohms
Rear left cable (No. 3)
5787-13,504 ohms
Front center cable (No. 4)
4882-11,392 ohms
Voltage regulator
Voltage output
1986-1993 models
13.8-15 VDC @ 75° F (24° C)
1994-2003 models
14.3-14.7 VDC @75° F (24° C)
Amps @ 3600 rpm
1986-1990 models
19 amps
1991-2003 models
22 amps
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст