Electrical Troubleshooting Manual - Part 1

Electrical Troubleshooting Manual - Part 1
 1998
GL1500 A/SE
ELECTRICAL
TROUBLESHOOTING MANUAL
Contents
How To Use This Manual
Troubleshooting Hints
Fuse Information
LCD Unit Display
Circuit Schematics (see Circuit Index)
Component Location Index
Component Location Photographs
Component Index
Circuit Index
Accessory Lights
Automatic Level Control
Brake Lights
CB Radio (Asp)
CB Radio (SE)
Charging System
Clock
Cornering Lights
Cruise Control
Engine Control System
Gauges
Ground Distribution
Handlebar Switch Illumination
Hazard Lights
Headlights
Horn
[llumination Lights
Indicators
Instrument Panel
License Plate Light
Low Fuel Warning
Marker Lights
Fairing and Trunk
Saddlebags
Qil Pressure Warning
Parking Lights
Position Lights
Power Distribution
Radiator Fans
Radio
Radio and Cassette
Reverse System
Speed Sensor Circuit
Spoiler Brake/ Taillight
SE Model only
Starting System
Taillights
Trunk Light
Turn Signal Lights
9-14
5-2
9-12
10-14
10-16
3-20
9-15
3-10
9-10
9-13
9-6
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., inc. — All Rights Reserved
MSV 8022 (9803)
How To Use This Manual
Page Numbering System
This manual divides the electrical system into individual sections. For example, Section 5
includes all Chassis Accessories. Component Location photographs are at the back of the
manual in Section 12.
Within a section, the pages are numbered using the section number, a dash, and then a
consecutive number beginning with zero. So if there are three pages in Section 2, the
pages will be numbered 2-0, 2-1, and 2-2.
Outline of Each Circuit Section
A Circuit Schematic (wiring diagram) starts off each section. Schematics show:
e how all the components within a circuit work together
current flow from the power source (top of page) to ground (bottom of page)
switch positions (shown “at rest” as if the ignition was off)
special instructions (“Solid-state: Do not check resistance”)
those circuits sharing a common power source or ground
A System Description (How the Circuit Works) appears in some sections;
it explains basic circuit operation.
A Troubleshooting guide also appears in some sections and provides step-by-step
instructions for diagnosis and repair. It includes symptom and diagnosis charts and self-
tests for all possible measurements in the system.
Model Abbreviations for 1998 used in this manual:
Asp — Aspencade
SE -— Special Edition
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., Inc. — All Rights Reserved 1 1
mm
MSV 8022 (9803)
- Symbols
How To Use This Manual
The abbreviations and symbols explained here are
used throughout the manual. You'll need to know
what they mean before you can use the schematics
effectively.
Wire Color Abbreviations
The following abbreviations are used to identify wire
colors in the circuit schematics:
BLK er AAA AAA black
BLU ........... e enerererecen.. blue
ВАМ dama a amas e dá à ca e HAS ВОД ВО brown
КОИМ wis © gion y cams a mens y xa y sen © НЫ green
PUR exa a mes e ua a aia E Ge Y MA 5 esse à gray
LTBLU ...................... light blue
LTGRN ..................... light green
ORN reed cea . orange
PNK... pink
RED auna ras a Sen в Gus © НЫЙ 3 Sal 5 SS E: red
WHT conc muaa xa y cu 6 Mee y SUN 7 Zas white
YEE. a um y nds Cama y UA & sms WE 5 oie yellow
Wires
A wavy line means the wire is
broken by the binding of the
book but continues on the
next page.
Wire insulation can be one
color, or one color with
another color stripe; the
second color is the stripe.
YEL/RED
EM" ОТ = 2
This means the current path
continues on another page.
The arrow shows direction of
current flow. To follow the WHT
white wire in this example,
you would turn to page 9-11
and look for the “R” arrow.
To $285
This means the branch of the
wire connects to another circuit. ORN
The arrow points to the name of
the circuit branch where the
wire continues. Name of Circuit
on page 9-11.
A broken line means only
some of the circuit is shown;
refer to the circuit listed for
the complete schematic.
|
See Ground
q Distribution,
page 2-10.
-M G100
Wire choices for options or
different models are labeled
and shown with a “choice”
bracket like this.
ORN
Without With.
Rear Speaker Rear Speaker
C309 C310
ORN ORN
| HOT AT ALL TIMES |
Where separate wires join, [—[—— ——= FUSE/
only the splice is shown; for
details on the additional
wiring, refer to the circuits
listed.
dun
Instrument Panel,
CB Transceiver
This dashed line means the
BLU/RED and RED/BLU wires
are both in connector C134.
Y BACK UP 1 RELAY
FUSE y POX
5A |
RED/YEL
523 523 6 5102
RED/YEL
RED/BLU
C134
BLU/RED
RED/BLU
1-2
Splices — “S”
Splices (S) are numbered and
shown as a dot. The location
and connection of these
splices may vary depending
on the harness manufacturer. BLK
BLK |
BLK
HN © =218
Connectors — “C”
Female
Each connector (C) is Connector
numbered for reference in the
Component Location Index,
Section 11. co
Male
Connector
The index also lists the total
number of cavities and the
color of the connector. Wires
may not be used in all cavities,
Empty
Cavity
This means the connector
connects directly to the GRY
component.
This indicates the connector
connects to a lead (pigtail)
wired directly to the
component.
This indicates a screw
Components
A solid border line means the
entire component is shown.
A broken border line indicates
that only part of the component
is shown.
The name of the component
appears next to its upper
right corner.
Notes about component
function follow its name.
Ground — “G”
This symbol means the end of
the wire is attached to a metal
part of the motorcycle.
Each wire ground (G) is
numbered for reference in the
Component Location Index,
Section 11.
This ground symbol (dot
and 3 lines) overlapping the
component means the housing
of the component is attached
directly to a metal part of the
motorcycle.
§ | Closed with
~~ 1 1 pedal depressed.
(cont'd)
1-3
How To Use This Manual
- Symbols (contd)
Switches
These switches move together;
a dashed line shows a mechanical
connection between them.
This is a relay shown with
no current flowing through
its coil. Unless otherwise
noted, all switches are shown
in their normal (rest) position,
with power off.
Normally Open
Closed
Contact
Shield
This represents RFI (Radio
Frequency Interference) GRN |
shielding around a wire. æ le a
The shielding is always к -® —
connected to ground. | !
e В 3 @ G103
Fuses
This means power is supplied
when the ignition switch is in ON.
| HOT IN ON |
Identification
GRN/BLK
Diode
This diode allows current to flow
only in the direction of the arrow.
Current rating
1-5
How To Use This Manual
— Circuit Schematic (cont'd)
Circuit schematics break the entire electrical system
into individual circuits. Electrical components that
work together are shown together so that you are
not distracted by wiring that is not part of the circuit
you are working on.
Each drawing is arranged so current flows from pos-
itive, at the top of the page, to ground, at the bottom
of the page. The “HOT” label at the top of a fuse
shows when the ignition switch supplies power to
that fuse.
Each circuit is shown completely and independent-
ly on one schematic. Other circuits getting their
power from the same point, or grounding at the
same point, are not shown. However, if other circuits
actually share some wires with the circuit shown, the
shared wires of the other circuits will also be shown.
LK
5 Deuba naa
5: page 2 21 Fi
iE HHH e TORPE:
НЕ РНЕ HEH lai a ; iii HEE cie
nes med A
Wires that connect to another circuit are shown with
an arrowhead pointing in the direction of current
flow. The name of the circuit or component that
shares the wiring is provided for reference. You can
check shared wiring by checking the operation of
the other circuits.
“See Power Distribution” means there are more con-
nections to other circuits that are not shown. All such
shared circuits are shown on the Power Distribution
circuit schematic. “See Ground Distribution” means
there are more shared ground circuits which are
shown on the Ground Distribution schematic.
WHT/GRN
HOT AT ALL TIMES d.
BOX
sx Power Distrbutio 2
PE pa ge 2 2 а
Lali HN WHT/GRN_ Turn via) Cancel
6 ===
Control Unit
LEFT
COMBI NATION
TT Ÿ SWITCH
GRN Distribution, ; :
S168 © a que
ETM
The sample Power Distribution schematic shows how voltage is supplied from the positive battery terminal to the
various circuits in the motorcycle.
Individual circuit schematics begin with a fuse. Power Distribution shows the wiring between the battery and the
fuses. By combining Power Distribution with any individual schematic, you get a complete picture of how voltage
is applied to the circuit.
You can use Power Distribution to speed your troubleshooting. If Power Distribution shows that an inoperative
circuitand a second circuit share a fuse, check the operation of the second circuit. If it works, you know the fuse is
good and voltage is available to the inoperative circuit. You can then continue troubleshooting.
WHT
Starting
System
INERTE Ti
cai ALTERNATOR
Page 3-12
В.К Вы к BRN/RED
| все вгоила
E Distribution,
“E page 2-10... Startin s t
‘page pa g System sg
@ G100
RED : EN ВНЕ 3 SWITCH
ETE
To FUSE/RELAY BOX on
page 2-4.
To FUSE/
RED/YEL RELAY BOX
оп раде 2—4.
LT GAN/BLK To FUSE/
RELAY BOX
LT GRN/BLK on page 2-2.
son Cas LT GAN/BLK
nm HAZARD
| a FLASHER f
od RELAY rama Е
Led Page 9-7 GRN/ e CAN
RED/YEL LT GAN/BLK BLK BLK _LTGAN ©103
e 5101 e e
5103 с73 5278 LT GHN AIR PRESSURE
RED/YEL LT GRN/BLK LT GRN/BLK EE ÿ STEH
RED/ L. Ad ASSEMBLY
RN/BLK ti
YEL C71 RED/YEL cer | НГ 6АМ LT GAN/BLK Li
5102 @ 5104 @
RED/YEL RED/YEL Palas
SAN C306 (Asp) RED/YEL C107
RED/YEL LT GRN/BLK LT GRN/
SEED " о о <. ca (SE) 18 a Hr GRES
: ) TALAR г E ICE TRANS-F = INSTRUMENT
) ue HT Le + NCEIVER Ea RACCCTTE ae ea ED
; | PANEL
= Page 9-18 вооон 2 Lo il
and 10-15 Page 10-0 IL 4
(contd)
1-7
How To Use This Manual
— Circuit Schematic (cont'd)
The sample Ground Distribution schematic shows which components share the same ground point.
г TE En. RELIEF Ea REAR Te 1 CRUISE
. SOLENOID iI a SUSPENSIÓN “A CONTROL
VALVE — E SOLENOID UNIT
| ans OMIS NN Page 5-5 I VALVE Page 4-3
п “Y BANK ™ = "1 REVERSE GRN
|. 4 ANGLE Г. ia | CONTROL
SENSOR
| : 1 Pages 3-8 1 Page 3-14
La = = and 3-12 o u À CRUISE
GRAN C42 CONTROL
GAN 5165 TION
E (SE Only)
Page 9-5
C33
WíCB RADIO.
г = FUEL
RIGHT
PUMP HORN
| Раде 3-2 Раде 5-0
г. РЕ т ENGINE
C186 (Asp or Int)
C127 (SE)
Tr 7 IN-LINE
vl CAPACITOR
GRN
C191
From $157
on following page.
GAN
GAN GAN
C22
GAN M s167
@
| GRN
C11
From C55 >
5168 @ оп раде 2-14.
“| GRN
2 G100 (PARTIAL) 2 G102
1-8
- Component Location
The Component Location Index (Section 11) lists every component, connector, and ground and
describes its location on the motorcycle. This index also gives references to component location
photographs which are found in Section 12.
Component Location Photographs (Section 12) show the exact location and appearance of
components, connectors, and grounds,
The Component Index (Section 13) lists all components and gives page references to all circuit
schematics in which each component appears.
Component Location Index (Section 11)
(Refer to Section 12 for photographs.)
Component Photo No.
Auxiliary Input Connector ..........-w=e===e—e... 55
Behind left fairing pocket
Bank Angle Sensor ....._—r.eeedserereereenene. 32
Component or Below right rear of seat,
Connector TA 5 on frame rail
a) À ERE HEN GER © 2 © ES OR RE Ra 45
а d instrument panel
Number of Cavities | и Р 55 с Photo
In Connector 0 (22-BLU) (SE) i aaa REE ARETE dae eee om ew ow EA Number
Behind left rear of seat in Section 11
Connector Color C10 (22-WHT) (Asp) ..........e.eesnrcecenoos 38
Below left rear of seat
Component Index (Section 13)
Acc Fuse 10A .............. 2-0, 5-2, 5-4, 7-6, 9-7,
10-0, 10-6, 10-15
Ace Terminal Fuse SÁ: .- wus x oxo x wa sw com x smn » 2-0
Accessory Terminal ..........e..eeeeee... 2-0, 2-12
Air Pressure Control
Switch Assembly .............. 2-0, 2-4, 5-4, 5-5
Air Pressure Sensor iii ania 5-4
Air Pump Assembly .................... 2-14, 5-5
Air Pump Fuse TOA ss cum « conv vn 0 con кож я 2-1, 5-4
Air Pump Relay ............eo seee. 2-0, 2-1, 5-4
How To Use This Manual
i Five-Step Troubleshooting
1. Verify The Complaint
Turn on all the components in the problem cir-
cuit to check the accuracy of the customer
complaint. Note the symptoms. Do not begin
disassembly or testing until you have narrowed
down the problem area.
2. Analyze The Schematic
Look up the schematic for the problem circuit.
Determine how the circuit is supposed to work
by tracing the current paths from the power
source through the circuit components to
ground. Also trace circuits that share wiring
with the problem circuit. The names of circuits
that share the same fuse, ground, or switch,
and so on, are referred to on each circuit sche-
matic. Try to operate any shared circuits you
didn’t check in step 1. If the shared circuits
work, the shared wiring is OK, and the cause
must be in the wiring used only by the problem
circuit. If several circuits fail at the same time,
the fuse or ground is a likely cause.
Based on the symptoms and your understand-
ing of the circuit's operation, identify one or
more possible causes of the problem.
3. Isolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis you
made in step 2. Keep in mind that a logical, sim-
ple procedure is the key to efficient trouble-
shooting. Test for the most likely cause of failure
first. Try to make tests at points that are easily
accessible.
4. Fix The Problem
Once the specific problem is identified, make
the repair. Be sure to use proper tools and safe
procedures.
5. Make Sure The Circuit Works
Turn on all components in the repaired circuit in
all modes to make sure you ve fixed the entire
problem. If the problem was a blown fuse, be
sure to test all of the circuits on that fuse. Make
sure no new problems turn up and the original
problem does not recur.
r Test Equipment
Voltmeter and Test Light
CAUTION: A number of circuits include solid-
state devices. Voltages in these circuits should
be tested only with a 10-megohm or higher im-
pedance digital multimeter. Never use a test
light on circuits that contain solid-state de-
vices. Damage to the devices may result.
On circuits without solid-state devices, use a test
light to check for voltage. A test light is made up of
a 12-volt bulb with a pair of leads attached. After
grounding one lead, touch the other lead to vari-
ous points along the circuit where voltage should
be present. The bulb will go oniif there is voltage at
the point being tested.
A voltmeter can be used in place of a test light.
While a test light shows whether or not voltage is
present, a voltmeter indicates how much voltage
there is.
Self-Powered Test Light and Ohmmeter
CAUTION: Never use a self-powered test light
on circuits that contain solid-state devices.
Damage to these devices may result.
Diodes and solid-state devices in a circuit can
make an ohmmeter give a false reading. To find
out if a component is affecting a measurement,
take one reading, reverse the leads, and take a se-
cond reading. If the readings differ, the compo-
nentis affecting the measurement.
An ohmmeter can be used in place of a self-pow-
ered test light. The chmmeter shows how much
resistance there is between two points along a cir-
cuit. Low resistance means good continuity.
Self-Powered Test Light
1-10
Circuits that contain solid-state devices should
only be tested with a 10-megohm or higher imped-
ance digital multimeter.
Use a self-powered test light to check for continu-
ity. This tool is made up of a light bulb, battery and
two leads. If the leads are touched together, the
bulb will go on.
A self-powered test light is only used on an unpow-
ered circuit. First disconnect the battery or remove
the fuse that feeds the circuit you are working on.
Select two points along the circuit through which
there should be continuity. Connect one lead ofthe
self-powered test light to each point. If there is con-
tinuity, the test light's circuit will be completed and
the bulb will go on.
Jumper Wire
Use a jumper wire to bypass an open circuit. A
jumper wire is made up of an in-line fuse holder
connected to a set of test leads. It should have a
five ampere fuse. Never use a jumper wire across
any load. This direct battery short will blow the
fuse.
Short Finder
Short finders are available to locate shorts to
ground. The shortfinder creates a pulsing magnet-
ic field in the shorted circuit and shows you the
location of the short through body trim or sheet
metal. Its use is explained in the following trouble-
shooting tests.
ETM
r Troubleshooting Tests
Testing for Voltage
This test measures voltage in a circuit. When test-
ing for voltage at a connector, you do not have to
separate the two halves of the connector. Instead,
probe the connector from the back. Always check
both sides of the connector because dirt and cor-
rosion between its contact surfaces can cause
electrical problems.
1. Connectone lead of test light to a known good
ground, or if you are using a voltmeter, be sure
you connect its negative lead to ground.
2. Connect the other lead of the test light or volt-
meter to the point you want to check.
3. Ifthe testlight glows, there is voltage present. If
you are using a voltmeter, note the voltage
reading. It should be within one volt of mea-
sured battery voltage. A loss of more than one
volt indicates a problem.
| HOT AT ALL TIMES
FUSE/
RELAY
BOX
= SWITCH
ay,
`
\ TESTLIGHT SP
m > or “a
VOLTMETER
(cont'd)
1-11
How To Use This Manual
- Troubleshooting Tests (cont'd)
Testing for Continuity
This test checks for continuity within a circuit.
When testing for continuity at a connector, you do
not have to separate the two halves of the connec-
tor. Instead, probe the connector from the back. Al-
ways check both sides of the connector because
dirt and corrosion between contact surfaces can
cause electrical problems.
1. Disconnectthe negative cable from the battery.
If you are using an ohmmeter, hold the leads to-
gether and adjust the chmmeter to read zero
ohms,
2. Connect one lead of self-powered test light or
ohmmeter to one end of the part of the circuit
you wish to test.
3. Connect the other lead to the other end.
4. Ifthe self-powered test light glows, there is con-
tinuity. If you're using an ohmmeter, low or no
resistance means good continuity.
Testing for Voltage Drop
Wires, connectors and switches are designed to
conduct current with a minimum loss of voltage. A
voltage drop of more than one volt indicates a
problem.
1. Connectthe positive lead of a voltmeter to the
end of the wire (or to the side of the connector
or switch) closest to the battery.
2. Connect the negative lead to the other end of
the wire (or the other side of the connector or
switch).
3. Turn on the components in the circuit.
4. The voltmeter will show the difference in volt-
age between the two points. A difference, or
drop, of more than one volt indicates a prob-
lem. Check the circuit for loose or dirty connec-
tions.
HOT AT ALL TIMES |
FUSE/
RELAY
BOX
7 SWITCH
EXEC
sep SOLENOID
1-12
ETM
Testing for a Short with a Test Light or Voltmeter
1. Remove the blown fuse and disconnect the load.
2. Connect a test light or voltmeter across the fuse
terminals. Make sure that the voltage is being ap-
plied to the fuse terminals. You might have to put
the ignition switch in RUN. Check the schematic
to see.
3. Beginning near the fuse/relay box, wiggle the
harness. Continue this at convenient points
about six inches apart while watching the test
light or voltmeter.
4, When the test light blinks or the voltmeter needle
moves, there is a short to ground in the wiring
near that point.
HOT AT ALL TIMES
FUSE/RELAY
BOX
(FUSE
REMOVED)
e «sf — SHORT TO
“xs TEST LIGHT
>. GROUND
1} or
VOLTMETER
cote
TA eed
BLU
LOAD
"DISCONNECTED
| SOLENOID
BE ee reos
Testing for a Short with a Self-Powered Test Light
or Onmmeter
1. Remove the blown fuse and disconnect the bat-
tery and load.
2. Connect one lead of a self-powered test light or
ohmmeter to the fuse terminal on the load side.
3. Connect the other lead to a known good ground.
4, Beginning near the fuse/relay box, wiggle the
harness. Continue this at convenient points
about six inches apart while watching the test
light or onmmeter.
5. Ifthe self-powered test light blinks or the ohmme-
ter needle moves, there is a short to ground inthe
wiring near that point.
BATTERY DISCONNECTED
FUSE/RELAY
BOX
(FUSE
REMOVED)
TE SHORT TO
GROUND
| SWITCH
E] SELF-
ON POWERED °"
| TEST LIGHT
A Or
| OHMMETER LOAD
233323
(cont'd)
1-13
How To Use This Manual
~ Troubleshooting Tests (cont’d)
Testing for a Short with a Short Circuit Locator
1. Remove the blown fuse. Leave the battery con-
nected.
2. Connectthe short finder across the fuse terminals.
3. Close all switches in series in the circuit you're | HoT aT ALL TIMES
testing. SHORT FUSE/
FINDER RELAY
“| BOX
4. Turn on the short circuit locator. It sends pulses of
current to the short. This creates a pulsing mag-
netic field around the wiring between the fuse/
relay box and the short.
5. Beginning at the fuse/relay box, slowly move the
short finder along the circuit wiring. The meter will
show current pulses through sheet metal and
plastic. As long as the meter is between the fuse
and the short, the needle will move with each cur-
rent pulse. Once you move the meter past the
point of the short, the needle will stop moving. ee
Check around this area to locate the cause of the
short circuit.
7 SWITCH
PULSING
MAGNETIC
FIELD
|
|
|
|
|
I
:
|
|
|
|
i
..NEEDLE STOPS
MOVING HERE — y,
18 «Mif— SHORT TO
GROUND
NO I
PULSING
MAGNETIC
HELD | ii SOLENOID
1-14
— Troubleshooting Precautions —
Before Troubleshooting
— Check the main fuse and the fuse/relay box.
— Check the battery for damage, state of charge,
and clean and tight connections.
CAUTION:
e Do not quick-charge a battery unless the
battery ground cable has been discon-
nected or you will damage the alternator
diodes. |
¢ Do not attempt to crank the engine with the
ground cable disconnected or you will se-
verely damage the wiring.
While You're Working
— Make sure connectors are clean and have no
loose pins or receptacies.
— Make sure multiple pin connectors are packed
with silicone grease.
Pack with silicone grease
CAUTION:
® Do not pull on the wires when disconnecting
a connector. Pull only on the connector
housings.
e When connecting a connector, push It until it
clicks into place.
e Refer to page 1-10 for cautions about trou-
bleshooting circuits that contain solid-state
devices. |
1-15
Fuse Information
- Fuse/Relay Box
ACC TERMINAL
TODD,
Oo
de
STOP
LIGHTS
RELAY
HEADLIGHTS
(HIGH)
RELAY
POSITION
RELAY
O
AIR PUMP HEADLIGHT
RELAY
®
IGN.
CRUISE
RELAY
Fuse Fuse ,
Number | Identification | AMPS Circuit or Component Protected
1 Acc 5 Optional accessories
Terminal
2 Horn/Turn/ 15 Horns, Horn turn relay coil, Position relay coil, Stop light relay coil,
Stop Relay Turn signal cancel control unit, Turn signal flasher relay coil
3 Stop 15 Brake lights
4 Fan 10 Cooling fans
5 Head 15 Headlights, Instrument panel indicators
6 Air Pump 10 Auto level control system
7 Parking 10 Air pump (outlet), Parking lights
8 Tait 15 Accessory lights; Instrument panel gauges, Instrument panel indicators,
Meter Cornering lights, Headlight relays, License plate light, Position lights,
Position Side marker lights, Taillights, Reverse system control, Handlebar illumination
9 RVS Start Reverse system
10 Acc 10 Air pump relay, CB radio, Stereo/cassette deck, Hazard lights,
Instrument panel indicator illumination, Wheei speed sensor
11 lgn. Start 15 Bank angle sensor, Charging system, Cruise control indicators,
Cruise Emission controls, Engine control module (ECM), Ignition coils,
Ignition/cruise relay coil, Starting system
12 Head Relay Headlights (high & low relay coils)
13 Back Up CB radio, Stereo/cassette deck, Instrument panel indicator illumination,
Trunk light
1-16
LCD Unit Display
When Radio is in the scan
mode, this indicator blinks.
Controlled by the AMB button.
This ambience circuit blends
frequencies from both channels
for a live performance effect.
Blinks on display when M button
on radio is pressed.
Y
Controlled by the mute switch / e | =
button, which automatically _ $, M UTE AM B 10 AN CH m _ Indicates which memory
m FA
Li
lowers radio volume so that channel has been
external noises may be heard. selected.
Displays AM or FM station; a > AM A hd UI
dependent on AM/FM switch. | ) ( ) ( ) |
4 a —
memo — st, | Y 4 DIA
Am aun" 0B "a=
When cassette player is loaded Controlled by headset
and radio is turned on, this will «LL speaker control knob.
indicate tape direction of play, Indicates that sounds are
present on the headsets
and not the speakers.
fast forward or rewind direction.
—
The Tape Music Sensor indicator
is displayed when a cassette is
engaged and the search lever
has been pushed upward or
downward. The cassette then ) (
advances or rewinds to the next am Y mt.
pause in music.
The corresponding direction
indicator blinks to indicate tape
direction.
Clock is displayed when
«K—— $ ignition switch is in BF ACC,
or ON.
PSI
—
|
To check air pressure in system,
press P Check button and time
will be removed from display and
air pressure will be shown in psi
* SE Models Only for American models, and kg/cm?
for Canadian models.
1-17
Power Distribution
r Circuit Schematic
WHT ES des
{ : e Ра
ВК Starting System Dries iol 5251
VEURE MAIN WHT
ESC BATTERY RED C41 A о
$ i MAIN [ed 1 STARTER Page 3-20
FUSE A | | RELAY A
30A | Page 3-11
ae | Sa E E
cali т Cal ALTERNATOR
ES я , BRN/RED Page 3-20
: , Starting System
& G100
a SAT or ener e IGNITION
Ea SWITCH
LT GRN/BLK BLK El BLU/ORN
Li yh SCTE IEE LE ut Fd GA ‘Ч ESTA = FUSE/
RELAY
BOX
‘ FI pain | To FUSE/
RED/YEL | L ren | RELAY BOX
8 y on page 2-4.
LT GAN/BLK To FUSE/
RELAY BOX
on page 2-2.
LT GRN/
RED/YEL LT GRN/BLK C103
® S101 BLK e LT GRN
\ S103 ¢73 5278 LT GRN AIR PRESSURE
RED/YEL LT GAN/BLK LT GAN/BLK r ren
М вс Î Ces | ASSEMBLY
lve C71 ReDNEL C91 TGANBLK D are === а Расе 5-2
C89 S102 e mr.)
S104 @
LT GRN/
RED/YEL
GAN RED BLK
FTE _ C306 (Asp) RED/YEL C107
LT GRN/ LT GRN/ LT GRN/
RED/YEL ABU C4 (SE) 18 BLK BLK
TOA TRUNK
J LIGHT
Page 9-13
CB TRANS-F
: CEIVER i
# Pages 5-1
and 10-16
#8
Teri
INSTRUMENT |
PANEL
ETM
J FUSE/
WHT RELAY
BOX
| вот iy |
© © © |
HORN/TURN/ > TAIL/METER/ AIR STOP |
STOP RELAY POSITION PUMP FUSE
| FUSE FUSE FUSE 15A
| sc [| 19A NA N WHT/RED
| WT WHT/BLU WHT/YEL From S106 ad |
оп раде 2-2. го — — = (5) |
WHT/BLU ei | | Contact i AIR |
| Contact y HEAD- * | | FUME, |
To HORN/TURN | | LIGHTS BLK hs is ios ad BE
| RELAY on le LOW) ©) Page 5-2 |
| PROPER 2 O Be TAIL r-=-10 |
à | Contact | HEAD- (MAIN) | Contact Jj STOP |
| | | LIGHTS Sia JLIGHTS |
| «нано о RELAY Т Pana 0.10
| Раде 8-1 See Ground ;
Distribution,
| page 2-8. |
La E Os a TEED TEED EEE Th SESE A MA o CA SEE SED PS EET O bel. Es JED GRAN SE ns Ok AT ED EC SE STE ME GE (EE AE
BRN/WHT
BRN/BLU @ G100
* BAN/WHT =
* SE models |
To splice on
page 2-5.
5115 e BAN/WHT
\ rr rrr BAN/WHT
\ \ See Indicators | ae me 1
| See Headlights page 7-0, BRN/WHT
\ page 8-0, Marker Instrument Panel | :
\ | Lights page 9-0 page 7-2 | | ‘ i
M | | + +, ‘
BRN/WHT BRN/WHT \ BAN/WHT BLK/GAN | \ |
\ 510 e To C10 | NA \_/ :
\ on page 2-5. RADIO CB
\ BRN/WHT BANAVAT | SWITCH SWITCH |
\ C73 | ILLUMI- ILLUMI- ;
\ BRN/WHT NATION NATION
\ ® S121 BRN/WHT | Page9-4 Page9g-4 |
La CUE Oo E So A os ERE al
= C94 \ BRN/WHT CB/RADIO SWITCH
\ mo C57 C58 ASSEMBLY
BRN/WHT BRNWHT | BAN/WHT (SE Models Only)
| г 1 ; | LOCK ON S116
| | | || sn BRN I Q BAN/WHT BRN/WHT
| | | | | | | pe Ea oo | C96 C70
pe F ow oy Re =
POSITION | f NA f AN = == = === = == в | Contact | y Contact |
| SWITCH | NA и |! — se E |
| Pages 9-3 | cRUISE CONTROL | BAN Laila NUH à
| and96 || SWITCH cio LEFT RIGHT
Les vi —] il ILLUMINATIÓN BAN CORNERING CORNERING
LEFT | Page 9-4 | LIGHT Lig RELAY | |
COMBINATION boon cs am am an ul RELAY sp Models Only
SWITCH RIGHT COMBINATION gap Models Page 9-3
SWITCH To S113 on 8 (cont'd)
(SE Models Only) page 2-4. age
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., Inc. — All Rights Reserved 2 1
MSV 8022 (9803) =
Power Distribution
— Circuit Schematic (cont’d)
From IGNITION SWITCH on page 2-0.
BLK
BLK BLK
® summer,
S105 S106
о From HORN/TURN/STOP RELAY FUSE Ш. | Ed
| оп раде 2-1. о | BOX
| | BLK
| ; ©, |
| BLK RVS START |
| ' FUSE |
| i 5A |
| Lip | ое | To TAIL (MAIN)
| e JBN = RELAY on
| RELAY © | BANWHT page 2-1.
|
— | do
| See Ground |
| Distribution, pus 6 WHT/GRN | GANT
| page 2-8. | F="—" REVERSE
Ea a ae a UL | | |LEVER
GRN | i | A SWITCH
Tu 1 | | WHT/GAN- |
; ? | WHT/GRN | . : E |
bm d | poor] POSITION =
C192 [1 ear |
ЕЕ | Page 9-7 |
GAN | Lad |
|--- - - WHT/GRN C10
S107 @ = === === ry
f See Ground E
Distribution, WHT/GAN C87
page 2-8. ==
GEN WHT/GRN C81 | eh |
5108 @ === == ет ето коки (| Ко
2 G100 WHT/GRN WHT/GAN TURN
da SIGNAL
WHT/GRN r «4 FLASHER
C320 | | RELAY
WHT/GAN F7 FRONT BRAKE | q age 9-7
| | LIGHT SWITCH tila
| Page 9-12 REAR BRAKE
Lia LIGHT SWITCH
Page 9-12
5110 @
wien | WHT/GAN
C90 X cas
wren N С99 WHT/GRN
WHT/GRN N Flia = я LEFT
F1 TURN SIGNAL 3 ; | HORN | COMBINATION
| | CANCEL CONTROL I SWITCH | swiTcH
| | UNIT |! | Раде 5-0
Le _— 4 Page 9-6 daa EE
BLK
Cheer
WHT RED/WHT BLK/LT GRN
See Engine Control System,
Starting System,
Charging System,
Reverse System,
Cruise Control
BRN/RED
т» C33 Cs?
BRN/RED
WHT RED/WHT
NA C11
WHT RED/WHT
RIGHT
COMBINATION
SWITCH
(cont’d)
2-3
Power Distribution
— Circuit Schematic (cont'd)
From IGNITION SWITCH on From IGNITION SWITCH on
page 2-0. page 2-0.
\
VYEUBLK | BLU/ORN AM
| 0 o | RELAY
| ce BANKINEG | FAN Hit NA 1 BOX
СОС ВЕ NE . © |
Е ton 5
LT GRN/YEL \
LT GRN/YEL ;
\
BLK/BLU ||
||
\
IN-LINE
DIODE B Y
| Outlet | PRESSURE Tage a
| Switch | CONTROL C22
i. 2 SWITCH
cs ce ASSEMBLY
Page 5-3
O 5111
BAN
C77 BLU
BRN
C78
AN BAN
eS Mee =
en Ei
th с 7 dd | LIGHT he
Page 9-11 From IGNITION SWITCHon ~~ Xo
page 2-1.
| 5112
ани as C109
C56 BRN
BRN _ a 0
S113 |
(A LICENSE
\ J PLATE a
LIGHT cs4 ™ RIGHT e LEFT
Page 9-11 fo NOISE 1 Y NOISE
SRN a. FILTER 1 | FILTER
Page 3-22 = Page 3-22
C85
5273 BRN BRN SLU а
® 5272 ы
MT "I RIGHT 13 LEFT
—7 CENTER OO
LOT avr rm dem mm mem LEFT À | MOTOR | 7 I MOTOR
| Assemeur = E LEFT Le. Lg
i Page 3-22 Page 3-22
(Optional) | T/ | SADDLEBAG
— | Page 9-10 no o ) FALSE — LIGHT
Ls tit éd аа «а — a Шо gE E Sm 5 ASSEMBLY
2-4
ETM
BAN/WHT
C86
BRN/WHT
E
Le — — 3
LEFT SIDE
TRUNK
MARKER
LIGHT
(Optional)
Page 9-1
From S115 From Tail (Main)
on page 2-1. Relay
on page 2-1.
BRN/WHT
BRN/WHT e
BAN/WHT BAN/WHT |
C10 C95 C69
BRN/WHT X BRN/WHT X
a (UN
\_/ CA
BAN/WHT LEFT FRONT RIGHT FRONT
ACCESSORY ACCESSORY
LIGHT LIGHT
(SE Models Only) (SE Models Only)
Page 9-14 Page 9-14
BRN/WHT S210
O == = = = == КО]
BRN/WHT BRN/WHT
BRN/WHT
С82
C76
ERN/WHT BRN BAN/WHT
RIA Г ny
| | ¿Ex 1
| | Nu |
(3)
SPOILER RIGHT SIDE
BRAKE/TAILLIGHT TRUNK
CONTROL MARKER
MODULE LIGHT
(SE Models Only) (Optional)
Page 9-15 Page 9-1
@ 5209 5211 @
BAN GAN
| LEFT \ LEFT REAR EN RIGHTREAR A RIGHT |
| ( ) BRAKE LIGHT/ N ACCESSORY ACCESSORY ) BRAKE LIGHT/ |
| АЕ Нант ) LIGHT \ © / LicHT — — TAILLIGHT |
| Page 9-10 Page 9-14 Page 9-14 Page 9-11 i
is ni ii Sina ain ite skies ia das Gn a ros a hl Sai A ee a air ii Da Uabc ai amm gu Gh ala cos a hk cis ad)
TRUNK LIGHT
ASSEMBLY
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., Inc.
MSV 8022 (9803)
- All Rights Reserved
2-5
Ground Distribution: G100, G102, G103, and G104
- Circuit Schematic
| ™ = "1 ENGINE r=" FUEL re WHEEL | = "1 LCD UNIT | | PANEL
{ | COOLANT | JeAauGe | [res D [Soldstae
| | [ENCERATURE Te ea |» i
| à. A SE . eo a.» Fage/4 EL. and 5- 1 i
| Ca Page 7-2 GRN/BLK a HE oe Sie |
E GAN/BLK — GAN/BLK |
| 2 = C107 E. cie |
GRN/BLK
C108
GRN/BLK GAN/BLK GRN/BLK
r= 1 FUEL
i | LEVEL
| | SENDER
L 4 Page 7-2 GAN/BLK
GAN/BLK C66
C112 GRN/BLK
C55
GAN/BLK
GRN/BLK
GRN/BLK
BATTERY
MT? SPEED | :
| + | LIMITER In
| 2 | FUSE =
13 184 Co
e
E
LT GRN
C22
LT GRN BLK
2
G104 27100 PARTIAL)
©
—
a
le
2-6
M >> ™ RELIEF rr 1 REAR "> "™ CRUISE FF" " TURN
| | SOLENOID | | SUSPENSION | | CONTROL : | SIGNAL
| i VALVE | | SOLENOID | ! UNIT i | SWITCH
É y Page 5-3 L 1 VALVE L _ Page 4-3 L age я 6
agen and 9-
Page 5-3 = 35
SAN GAN
A" RIGHT
® i | CORNERING
5164 | | Sg
La au ей
mA" BANK г == "1 REVERSE Page 9-3
3 | ANGLE | | CONTROL C70
| | SENSCH. À 1 | Eos i 24 Models CRUISE
La + Pages 3-10 Lu age
y Onl CONTROL
GEN and 3-20 Caz y SWITCH
Ci1 GRN GRN ILLUMINA—
GRN S165 TION
a м E
GAN E
Esa Without CB Radio !
r " FUEL SONT |
| - — — FRON
With CB Radio | PUMP ACCES- : |
re” FUEL Page 3-2 RIGHT SORY ;
i | PUMP E HORN LIGHT is: 3
A ENGINE La J sod Fa
| = W C186 (Asp) a { > { >
MODULE p
| +42 ; (ECM) GAN @ C127 (SE) GAN Models ui C94
is cuss id ans 3-0 C178 (SE) ©
C49 GAN GAN
== "19 IN-LINE == RIGHT GRN
| CAPACITOR / \COR- C69 C57
D \ _/ NERING
GAN GR = LIGHT GRN
Page 9-3
C183 (Asp) GEN Er SE GRN GRN
C178 (SE) C69 GRN Models
GRN GRAN Only
— C191
jen 1
EE
GRN
— — C—O Cr ee GE O E os a a a сны GREE LD Die
es Eee SOI ET ELT A A a a Kt A A UE—
From S157
on page 2-8.
From C55
GRN
on page 2-10.
GRN
C22
C115
Revised: May, 1998, 1998 GL 1500 ETM
©1998 American Honda Motor Co., Inc. — All Rights Reserved
MSV 8022 (9803)
Ground Distribution: G100, G102, G103, and G104
- Circuit Schematic (cont'd)
| HEAD- HEADLIGHTS (LOW) | RELAY
HORN/ STOP TAIL LIGHTS RELAY BOX
| TURN LIGHTS (MAIN) (HIGH) Page 8-1 |
| RELAY RELAY RELAY RELAY E — 1
ere EA Aa E ACCESSORY |
| | ¡O I~ 1 [о TERMINAL 1 | |
| | coi | | coi | | coi ] lc | tb — |
| X X Y |
: |
a ci nt cm сон ой ао ко ао а не “о на сы а MIES SEA (e OE NE (OREA Ve i ss ai an il]
TURN
CB CRUISE SIGNAL
TRUNK SWITCH CONTROL CANCEL
LIGHT CASSETTE (DRIVER) VALVE CONTROL
SWITCH LEFT Pages 10-15 UNIT UNIT
Page 9-13 HORN and 10-17 Page 4-3 Page 9-6
1 Pageso CB/RADIO PTT rea Ea
! i Pray SWITCH | | | | | |
| | ASSEMBLY i | i | | |
cu Ka (SE Models pu. à És Lia
C179 Only)
Page 9-4 GAN GRN
e poe o y C131 coo
ein ce, 9
| FED , E sn
9
C89 | + I |
L id Jd C23(SE) GRN
GAN GAN C20 (Asp)
LEFT
FRONT Ch
ACCESSORY GAN GAN SIDE GAN C90
LIGHT STAND
Page 9-14 SWITCH
pa Pages 3-1
€ x and 3-11
— С179 & С23 | 1
GAN
SE | |
Models La aye =}
Only
GAN GAN
C95 C28
ня C192
== == = —
PTT Tor
e : N
в y 5 ® \
|
To S167
on page 2-7.
Revised: May, 1998, 1998 GL1500 ETM
2-8 ©1998 American Honda Motor Co., Inc. — All Rights Reserved
MSV 8022 (9803)
ETM
\
| LIGHT
ASSEMBLY
Pages 9-9,
| 9-12
| >. RIGHT REAR am =
/N RIGHT
i С J E” ( ) BRAKE LIGHT/ \ 3 REAR TURN
aa “= = TAILLIGHT —/ SIGNAL LIGHT
| — de ao o Ge EET TT ey a ETT OE E NED CD AD SUE EA EEE RE o ES UU EEF RJ
GRAN
GAN
® S157
GRN
C76
GRN
q: —
| LEFTREAR |
LICENSE RIGHT SIDE TRUNK ESSORY
TO PLATE MARKER LIGHT TRUNK LIGHT ASSEMBLY eur
LIGHT Optional) Pages 9-9, 9-10, 9-12 Page 9-14 |
pdt wy Page 9-11 age 9-1 Г — — — === = = = = = = = e e т |
(7) BRAKE ) INET rN 7 SAN о E un | es LEEY ( \ $
LIGHT GAN GAN GRN LIGHT TAILLIGHT ;
L —F Bi “— GAN GRN DD es @ 5271 Las me GE SED GaN GENS EDS GEER mem ms emmy WEE Ams weve a un a
GRN S270 GAN GRN GAN . GAN
5160
C56 C75
GRN GRN GRN
GRN C75 SPOILER
BRAKE/
HAZARD и S159 CONTROL
C77 LEFT SIDE TRUNK N
FLASHER LEFT SADDLEBAG MARKER LIGHT STARTER RELAY MODULE
RELAY LIGHT ASSEMBLY (Optional) REGULATOR (SE Models)
Page 9-7 Page 9-12 Page 9-1 Page 3-24 Page 9-15
Là (TEEN ENCINA NU à (|
E ) LIGHT/ NIN ZN
| —— TAILLIGHT | can CN £ à | |
Le el GAN GAN | L à bad
o i sn a) S267 © mu @ C329
C86 w C330
9 E C331
r= = LEFT (NN LEFT GAN SEN
| | CORNERING \ J CORNERING SAN
| ge LIGHT 5149 $ REED E SPOILER
RELAY Page 9-3 BRAKE/
br Page93 cr can 5150 TAILLIGHT
(SE Models)
we AE се C10 Page 9-15
GAN Only GAN GAN An GRN
TE AA ee es C192
\ Е | 2 C330
/ | |
(сопРа)
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., Inc. — All Rights Reserved
MSV 8022 (9803)
Ground Distribution: G100, G102, G1
03, and G104
— Circuit Schematic (cont'd)
i RIGHT TURN LCD HIGH PANEL
SIGNAL ILLUMINATION UNIT BEAM Pages 7-2,
| INDICATOR TACHOMETER LIGHTS p — = |LLUMINATION INDICATOR | 7.3, 7-4
Го 4 KEN lv. € NN 7
| NA UU IP NA Ки |
| | 4
! |
| GAN |
i |
| |
| o ;
| |
LEFT RIGHT RIGHT | LEFT TURN
HEADLIGHT LEFT HEAD- HEADLIGHT | SIGNAL SPEEDOMETER | RIGHT FAIRING RIGHT FRONT
POSITION HEAD- LIGHT POSITION INDICATOR ILLUMINATION MARKER LIGHT TURN SIGNAL/
LIGHT LIGHT Page LIGHT | pal | (Optional) POSITION LIGHT
Page 8-1 Page 8-1 8-1 Page 8-0 | A AN г \ | Page 9-0 Page 9-8
€ O fx [ef da od | (TN ON
\_/ | | NA и
| GAN |
| | GAN SAN
\ |
® нони ® 5174 e
52
C66 GAN GAN
s175 e
SAN
RADIO
ASSEMBLY — NOISE $172 e
Page 5-3 Des LEFT FRONT TURN LEFT FAIRING
4998 =: SIGNAL/POSITION MARKER LIGHT
REE RUN GAN LIGHT (Optional)
Ï ; | Coa Page 9-8 Page 9-0
| os
Las Baa С о 4 3
GAN GAN
C106 C182
GAN
GRN GRN GAN
“ : C97
GRN GAN
S177 € ©
SAN S176
C55
GAN
To S168
on page 2-7.
2-10
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Matar Co., Inc. — All Rights Reserved
MSV 8022 (9803)
2-11
Engine Control System
— Circuit Schematic
poa
(11) IGN. START
RELAY
CRUISE FUSE | Bes
É |
WHT i |
® 5187 | |
== al WHT
r — Tes GE |
; IGN/CRUISE |
| RELAY |
|
WHT |
La CE ES ES CES O GU GENE SEER EET TEES TES CEE Ee. cm is wi ems is jm i mb e
RED/WHT
BLK/LT GAN
y 510: e BLK/LT GAN
VERE 0 A,
Starting System
(Bank Angle Sensor) BLK/LT GRN Na
BLK/LT GRN
y a ® S181 BLK/LT GAN
BLK/LT GAN C57 BLK/LT GRN cee
| Start/Reverse COMBINATION BLK/LT GRN Charging System
i ENGINE | SWITCH C120 BLKLTGRN BLKLTGAN С119
| SWITCH | BLK/LT GAN À 5189 BLK/LT GAN
BLK/WHT al HET AIR JET
Kai SOLENOID SOLENOID
BLK/WHT y VALVE #2 VALVE #3
WHT RED/WHT À RED
® 5188 C119
C120
BLK/WHT \ BLK/WHT RED/WHT |
©® елены) symm но = — C55
WHT
S195 RED/WHT |
y L ———— a DA EE cas
Cruise Ignition | Switched Ground Speed Switched Ground \
Control | ‹ El f Sig mai Switched \
| Switched Switched — Switched Output Output Ground )
L 13 26 EE 16, 11 . 12
BLKWHT NP TT TW TTT Ca
YEL/WHT YEL/BLU YEL/RED WHT/BLK YEL/BLU GRN
=== fe, C54 C33
YEL/WHT YEL/BLU WHT/BLK
BLK/WHT BLK/WHT
BLK/WHT Instrument Panel
S184 @ YEL/BLU se Sensor (Tachometer)
ai IGNITION |
COILS | See Ground
— Distribution,
; page 2-7.
@ Gioo
SPARK PLUGS 7
ВКЛ САМ
C315
BLK/LT GRN
PULSE SECONDARY
AIR INJECTION
(PAIR)
SOLENOID VALVE
BLK/RED
C315
BLK/RED
C49
CONTROL
\ Sufiohed Ground : El E | MODULE
Over- nt Side | (ECM)
Neutral 2nd. 3rd. 4th. Drive | LE à Stand | Solid: e:
) Input. Input Input Input Input he Input ; 1 Do not check
MEMO MP ee C49 See Starting System,
ЗН System GRN/WHT GRN/WHT Reverse System,
an *
everse System SENORN dd Indicators $257 O FEE =x pages 3-11 and 3-25.
LT GRN/ BLK/ M WHT/ RED/ GRN/
RED YEL RED WHT ORAN GRN/ORN GRN/WHT 1 YEL/BLK YEL/BLK
S185 € er A |
GAN/ Cruise
LT GAN/RED а êtes Sen REDWHT Control GRNMWHT \ C28
S144 Y E q SIDE STAND
LT GAN/RED 1 =i SWITCH
WHT
C59
WHT/ RED/
LT GRN/RED TT WHT cas
> GEAR GRAN
a POSITION |
| SWITCH See Ground
7 a i Distribution,
0 I page 2-8.
= &
= G100 (cont’d)
3-1
Engine Control System
— Circuit Schematic (cont'd)
FUEL
PUMP
GRN/BLU
C127
C178
GRN/BLU
ada 17 | CONTROL
Coolant Ambient Speed Input Fuel Pump | MODULE
во Pm Input Temp. Input Common ’ mont cam, Gontior Output | | (ECM)
_ тн — TT a NR — — C49 Do not check
PNKWHT op EE as C63 BLK/BLU
C60 IGNITION IGNITION
PULSE WHT/BLU Y PULSE
PNK/WHT WHT/YEL GENERATOR GENERATOR
C314 #2
ENGINE INTAKE AIR dE Wa ENGINE
COOLANT CURE > RUNNING
ure on
(ECT) C314
SENSOR
GRN/BLK GRN/BLK C63
GRN/BLK
Lee TN
Im \
Asp
s19
| Asp With Without
SE | CB Radio CB Radio
y |
| suce
C178 C184
BLK/BLU BLK/BLU BLK/BLU
“1 IN-LINE г 7 IN-LINE
| CAPACITORD | | CAPACITOR D
al Ls
BLK/BLU
FUEL
PUMP
C186
"1 IN-LINE 1 IN-LINE
— | CAPACITORD | CAPACITOR D
J 3
GRN
C178 С183
GAN
; C191 C191 c191 ,
Е
Cid
T C191
| — See Ground
| Distribution,
BB pañe2-7.
a
2 G100
3-2
- How the Circuit Works
ETM
Engine performance is controlled by the engine
control module (ECM). The ECM receives battery
voltage when the engine stop switch is in RUN. The
ECM monitors coolant temperature, intake air
temperature, gear position, and engine speed. It
also controls engine operation by operating several
solenoid valves, ignition coils, and the fuel pump.
Carburetor Air Jet (CAJ) Solenoid Valves
The CAJ solenoid valves receive battery voltage
from the ignition/cruise relay with the ignition ON.
They receive a ground control signal from the ECM.
Pulse Secondary Air Injection (PAIR)
Solenoid Valve
The PAIR solenoid valve receives battery voltage
from the ignition/cruise relay with the ignition ON. It
is controlled by a ground control signal from the
ECM.
Ignition Coils
The three ignition coils receive battery voltage with
the ignition ON and the engine stop switch in RUN.
Each coil is fired individually when the ECM grounds
the corresponding coil control line. The ECM can
vary ignition timing based on other sensor
information.
Gear Position Switch
The gear position switch supplies five input circuits
to the ECM for the positions N, 2, 3, 4, and OD. The
respective circuits are ground when in the
associated gear and open otherwise.
Side Stand Switch
The side stand switch sends a ground signal to the
ECM with the side stand switch in UP and is open in
DOWN.
Intake Air Temperature (IAT) Sensor
The intake air temperature (IAT) sensor is a resistor
that increases resistance with a decrease in
temperature and decreases resistance with an
increase in temperature. The IAT sensor sends this
resistance signal to the ECM through the GRN/BLK
sensor common and the GRY ambient air
temperature input circuit.
Ignition Pulse Generators
The ignition pulse generators are coils that generate
a magnetic pulse when the crankshaft magnet
passes by the pulse generator pickups. This pulsing
signal conveys crankshaft position and engine RPM
information to the ECM. One end ofthese generators
is tied to the GRN/BLK sensor common. The ignition
pulse generator signals are sent to the ECM through
the WHT/YEL and WHT/BLU circuits.
Fuel Pump
The fuel pump is a DC motor that receives ground
through the GRN circuit. It receives a voltage control
signal from the ECM.
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature (ECT) sensor is a
resistor that increases resistance with a decrease in
temperature and decreases resistance with an
increase in temperature. The ECT sensor sends this
resistance signal to the ECM through the GRN/BLK
sensor common and the PNK/WHT coolant
temperature input circuit.
- Troubleshooting
SYMPTOM
DIAGNOSIS
e Engine cranks but does not start.
e Engine runs poorly.
e Do Isolation Procedure 1.
e Do Isolation Procedure 2.
(cont'd)
3-3
Engine Control System
~ Troubleshooting (cont'd)
ISOLATION PROCEDURE 1
Note: Perform all checks in order.
If a result is incorrect, go to the test referenced.
If a result is correct, perform the next check.
1
Ground (GAN)
Continuity to ground.
If not, service GRN circuit for an open.
see 4 & 5 |
[3 Sensor Common (GRN/BLK)
C49 — Continuity to ECT sensor, IAT sensor
Ignition Coil Control (YEL/BLU) ECM aNdIENMiDN pulso generara.
Battery voltage with ignition switch ON + 26 | 43°
and engine stop switch in RUN. ill e
If not, go to test A. 25 | 12
24|11 5 |
23| 10 Ignition Pulse Generator #1 Input
(WHT/YEL)
22| 9 Resistance to GRN/BLK sensor common
is 400-500 ohms at 68°F (20°C).
21| 8 (= If not, go to test B.
20| 7
19| 6 4)
185 Ignition Pulse Generator #2 Input
17| 4 (WHT/BLU)
Resistance to GRN/BLK sensor common
16 a is 400-500 ohms at 68°F (20°C).
; If not, go to test C.
15 | 2 |
1
14117 6 |
Fuel Pump Control Output (BLK/BLU)
Momentarily jumping to battery voltage
— operates fuel pump.
If not, go to test D.
7]
Ignition Input (BLK/WHT)
Battery voltage with ignition switch ON and
stop engine switch in RUN.
If not, check BLK/WHT circuit for an open.
If circuit is OK, service right combination
switch.
ISOLATION PROCEDURE 2
Note: Perform all checks in order.
If a result is incorrect, go to the test referenced.
If a result is correct, perform the next check.
If a box is not numbered, do not check.
Г
Side Stand Input (GRN/WHT)
Continuity to ground with side stand UP
and open with side stand DOWN.
If not, check GRN/WHT and GRN circuits
for an open or short to ground. C49
If circuit is OK, service side stand switch. ЕСМ)
En 26 13N
Neutral Input (LT GRN/RED) 25 | 12
Battery voltage with ignition switch ON, 24 | 11
reverse lever in FORWARD, and —
transmission not in NEUTRAL. > 93
If not, service neutral indicator circuit for 10) [5]
GH Span Bt HiT DARIN = 22| 9 Overdrive Input (GRN/ORN)
ero volts in : A
If not, check LT GRN/RED circuit and 21| 8 EO TG]
gear position switch for an open. — >! 20| 7 |e— indicator control circuits, and bulb for
E an open or short to ground.
€ 19| 6 Zero volts in Overdrive (OD).
2ND Gear Input (BLK/YEL) If not, check GRN/ORN circuit and
Continuity to ground with transmission in 18| 5 gear position switch for an open.
2nd gear otherwise open. 17| 4
If not, check BLK/YEL circuit for an open |
or short to ground between ECM and 16 | 3
gear position switch.
If circuit is OK, service gear position switch. » 15 | 2
14 | 1
5] y
3RD Gear Input (WHT/RED)
Continuity to ground with transmission in
3rd gear otherwise open.
If not, check WHT/RED circuit for an open
or short to ground between ECM and
gear position switch.
If circuit is OK, service gear position switch.
a
4TH Gear Input (RED/WHT)
With ignition OFF, connect test lamp be-
tween terminal indicated and battery volt-
age. Lamp lights in 4th gear and is off in all
others.
If not, check RED/WHT circuit and gear posi-
tion switch for an open or short to ground. (cont'd)
3-5
Engine Control System
rm Troubleshooting (cont’d)
ISOLATION PROCEDURE 2 (cont'd)
7
Ignition Coil Control (YEL/BLU)
4 ohms.
If not, go to test E.
Resistance to pin 2 (BLK/WHT) is about
[8
Ignition Coil Control (YEL/RED)
4 ohms.
If not, go to test F.
Resistance to pin 2 (BLK/WHT) is about
El
Ignition Coil Control (YEL/WHT)
m
(GRY)
Resistance to GRN/BLK ECM sensor
and 200 to 400 ohms at 176°F (80°C).
If not, go to test L.
Intake Air Temperature (IAT) Sensor Input
common is 2k to 3k ohms at 68°F (20°C)
Engine RPM Output Signal
(Asp and SE models only) (WHT/BLK)
Continuity to cruise control unit
connector C135.
ho
Carburetor Air Jet (CAJ)
Solenoid Valve #2 (RED/WHT)
Battery voltage with ignition switch ON.
If not, go to test H.
[11]
Carburetor Air Jet (CAJ)
Solenoid Valve #3 (RED)
Battery voltage with ignition switch ON.
If not, go to test I.
C49 Resistance to pin 2 (BLK/WHT) is about
(REA) 4 ohms.
26 | 13\,| If not, go to test G.
25 12
24111 Tachometer Output Signal (YEL/BLU)
Continuity to instrument panel
23|10 connector C66.
22| 9
21| 8 13]
20| 7 Engine Coolant Temperature (ECT)
Sensor Input (PNK/WHT)
191 6 Resistance to GRN/BLK ECM sensor
> common is 2k to 3k ohms at 68°F (20°C)
18| 5 and 200 to 400 ohms at 176°F (80°C).
If not, go to test K.
17] 4
16 [3 | hal
1 Pulse Secondary Air Injection (PAIR)
14 | 1 Jed Solenoid Valve (BLK/RED)
= Battery voltage with the ignition switch ON.
If not, go to test J.
3-6
Test A: Ignition Coil Input Test
Disconnect C54. Turn the ignition switch ON and place engine stop switch in RUN.
Check that there is battery voltage at BLK/WHT (ECM side of C54) circuit.
If yes, go to test G.
If no, service BLK/WHT circuit for an open.
Test B: ignition Pulse Generator #1 Input Test
1. Disconnect C63 and connect ohmmeter across WHT/YEL and YEL circuits at generator side
of connector. Resistance should be about 400-500 ohms.
If yes, check YEL, GRN/BLK, and WHT/YEL circuits between ECM and ignition pulse generators
for an open.
If no, replace ignition pulse generator.
Test C: Ignition Pulse Generator #2 Input Test
1. Disconnect C63 and connect ohmmeter across WHT/BLU and BLU circuits at generator side of
connector. Resistance should be about 400-500 ohms.
If yes, check BLU, GRN/BLK, and WHT/BLU circuits between ECM and ignition pulse generators
for an open.
If no, replace ignition pulse generator.
Test D: Fuel Pump Control Test
A Gasoline is flammable and is explosive under certain conditions.
LAU NIDIEN Do not smoke or allow flames or sparks in your working area.
Immediately wipe up any spills.
1. Disconnect C184 (except Asp model) or C185 (Asp model). Momentarily jumper BLU circuit
(fuel pump side) to battery voltage. Fuel pump should run.
If yes, service BLK/BLU circuit between ECM and C184 or C185 for an open.
If no, go to step 2.
2. Disconnect C127 (except Asp model) or C186 (Asp model). Check GRN circuit (Asp model) or
GRN/BLU circuit (SE model) for continuity for ground.
If yes, service fuel pump.
If no, service GRN or GRN/BLU circuit for an open.
Test E: Ignition Coil Input Test
1. Connect ohmmeter across BLK/WHT and YEL/BLU circuits at ignition coil side of C54.
Resistance should be about 4 ohms.
If OK, service YEL/BLU circuit between ECM and C54 for an open.
If not OK, service ignition coil.
(cont'd) |
3-7
Engine Control System
— Troubleshooting (cont'd)
Test F: Ignition Coil Input Test
1.
Connect ohmmeter across BLK/WHT and YEL/RED circuits at ignition coil side of C54.
Resistance should be about 4 ohms.
If OK, service YEL/RED circuit between ECM and C54 for an open.
if not OK, service ignition coil.
Test G: Ignition Coil Input Test
1.
Connect ohmmeter across BLK/WHT and YEL/WHT circuits at ignition coil side of C54.
Resistance should be about 4 chms.
If OK, service YEL/WHT circuit between ECM and C54 for an open.
If not OK, service ignition coil.
Test H: Carburetor Air Jet (CAJ) Solenoid Valve #2 Input Test
1.
Disconnect C120 (CAJ solenoid valve). Turn ignition ON and check for battery voltage at
BLK/LT GRN circuit.
If yes, go to step 2.
If no, service BLK/LT GRN circuit for an open.
Connect ohmmeter across RED/WHT and BLK/LT GRN circuits (solenoid side).
Resistance should be about 32 chms.
If yes, service RED/WHT circuits for an open between C120 and ECM.
If no, replace CAJ solenoid valve.
Test I: Carburetor Air Jet (CAJ) Solenoid Valve #3 Input Test
1.
Disconnect C119 (CAJ solenoid valve). Turn ignition ON and check for battery voltage at
BLK/LT GRN circuit.
If yes, go to step 2.
If no, service BLK/LT GRN circuit for an open.
Connect ohmmeter across RED and BLK/LT GRN circuits (solenoid side).
Resistance should be about 32 ohms.
If yes, service RED circuits for an open between C119 and ECM.
if no, replace CAJ solenoid valve.
Test J: Pulse Secondary Air Injection (PAIR) Solenoid Valve Input Test
1.
Disconnect C315 (PAIR solenoid valve). Turn the ignition ON and check for battery voltage
at BLK/LT GRN circuit (harness side).
If yes, go to step 2.
If no, service BLK/LT GRN circuit for an open.
Connect ohmmeter across BLK/RED and BLK/LT GRN circuits (solenoid side).
Resistance shouid be about 32 ohms.
If yes, service BLK/RED circuits for an open between C315 and ECM.
If no, replace PAIR solenoid valve.
3-8
Test K: Engine Coolant Temperature (ECT) Sensor Input Test
1.
Disconnect coolant temperature sensor. Connect ohmmeter across sensor terminal.
Resistance should be less than 2k-3k ohms at 68°F (20°C) and decrease with a
temperature increase.
If yes, check GRN/BLK and PNK/WHT circuits for an open between sensor and ECM.
if no, replace sensor.
Test L.: Intake Air Temperature (IAT) Sensor Input Test
1.
Disconnect C314 (IAT sensor). Connect chmmeter across sensor terminal.
Resistance should be less than 2k-3k ohms at 68°F (20°C) and decrease with a
temperature increase.
If yes, check GRN/BLK and GRY circuits for an open between sensor and ECM.
If no, replace sensor.
3-9
Starting System
— Circuit Schematic
ВЯ ® |ReAY
| $ IGN. START e 11111 BOX
| Hse sur |
| 15A Jruse |
L {ss |
rs OEM WER li a
WHT Le Ni -
S187 @ = |
N i о ————— o a mn ais Naa ый
Pa | |
7 IGN, [CRUISE |
| RELAY |
| = a . |
x BRN/WHT
WHT | REowaT E |
т» СЗЗ C32
WHT | cow] BLK/ LT GRN
MN————— C11
= See Engine
Control am:
uw page 3-0
1 BANK 1
ANGLE C57
SENSOR C92
BLK/ BAN
LT GAN
ar PE ee — | COMBINATION
: =E | STARTER/ SWITCH
C11 FREE | REVERSE 1
GRN y | y PUSH SWITCH |
See Ground | 3 |
Distribution, J REVERSE
page 2-7. | LEVER SWITCH
2 G100 *
C92
YEL/RED
\ System
YEL/RED Reverse
S198 € ===> System \
YEL/RED
Radio/Cassette \
YEL/RED Deck,
CB Transceiver \
QU
To STARTER RELAY A To S303
on page 3-11. on page 3-11.
3-10
ETM
From REVERSE LEVER
SWITCH on page 3-10.
From STARTER/REVERSE
SWITCH on page 3-10.
YEL/RED L
BLK/WHT
See Power
Distribution,
page 2-0.
WHT
BLK/WHT BLK
BLK/WHT mo N STARTER ig | BATTERY
haat C32 RELAY A 53
BLK/WHT 1 =
C66 BLK/WHT se
BLK/WHT mena
r 1 INSTRU- BAN/RED
| | MENT S302 @
| NEUTRAL | PANEL Fame |
INDICATOR e я REVERSE $227 i wt vm ve See Ground
| [N] | | Sane Ÿ Distribution,
Laid iad I | 1 Reverse C312 page 26.
Loge System : ÿ /
LT GRN/RED
' YEL/RED Ï IN-LINE 2 G100
LURE B
C66 C32 BRN/RED a
LT GRN/RED YEL/RED
css 0 Re C30 YEL/RED
roms —]] REVERSE
x SWITCH
— |RELAY
STARTER
LT GRN/RED RELAY B
BLK/RED BLU/RED
GRN/RED
— — — — — — — — — da Reverse
LT GAN/RED BLK/RED BLU/RED GAN/RED System
—_— E == ; | DIODE
u_u wr 0 je Da ie D1} ASSEMBLY
LT GRN/RED Y
GAN/RED Реза LT GRN/RED SH
C32 System O S306
SANAED X rai LT mn |
свм/ВЕр М = C32 BLK
C325 Engine
CLUTCH Control
SWITCH LT GAN/RED vo Y
Closed when
lever depressed. e romo Y
5186
GRN/WHT Ï C326 Arline LT GRN/RED
C181 Y a Reverse
Reverse
GRN/WHT GRN/WHT System System
s257 € rares Starting System >
YEL/BLK Pd
SRT mer Indicators SAME)
C28 LT GRN/RED ©
GRN/WHT | YEL/BLK i MOTOR
1 SIDE STAND =
| SWITCH =
GEAR F Tif ji
POSITION :
Sehen REVERSE
See Ground | J SWITCH
Distribution, GRN E | 1 open in
age 2-8. à ;
e M G100 L
3-11
Starting System
r How the Circuit Works
The starting system for the Asp and SE models is
made up of the following components:
— Bank angle sensor
— Clutch switch
— Gear position switch
— ignition/cruise relay
— Reverse diode assembly
— Reverse lever switch
— Reverse switch
— Reverse switch relay
— Side stand switch
— Starter relay A
— Starter relay B
— Starter/reverse motor
— Starter/reverse switch
The starter/reverse switch receives battery voltage
from the ¡GN/cruise relay when the ignition is
switched ON. The bank angle sensor supplies
ground to the IGN/cruise relay.
e The starting system is activated when the driver
presses and holds the starter/reverse switch.
e Voltage from the tGN/cruise relay is then sent
through the reverse diode assembly, reverse
switch relay coil, and gear position switch to
ground.
® The reverse switch relay energizes and
completes a ground path from the coil of starter
relay A to ground through the reverse diode
assembly, clutch switch, and the side stand
switch.
e Starter relay A energizes and applies battery
voltage to the coil and contacts of starter relay B
when the reverse switch is in the FORWARD
position.
e Starter relay B energizes and applies voltage to
the starter/reverse motor. The starter motor
turns to crank the engine.
3-12
AR
— Troubleshooting
SYMPTOM
DIAGNOSIS
e Starter and reverse systems do not
operate but the neutral indicator operates.
Weak battery or poor terminal
connections.
Blown RVS Start fuse.
Open circuit at reverse lever switch or
faulty starter/reverse motor; do test A2.
e Starter and reverse systems do not
operate and the neutral indicator does not
operate.
Poor battery terminal connections.
Blown IGN Start Cruise fuse.
Open circuit or faulty bank angle sensor,
IGN/cruise relay, starter relay A;
do test A1.
e Starter operates in neutral, but not in gear
with clutch lever depressed and side
stand switch UR
Open circuit or faulty reverse diode
assembly, clutch switch, or side stand
switch; do test C1.
e Starter operates with clutch lever
depressed and side stand switch UP, but
not with clutch lever released and gear
selector in NEUTRAL.
Open circuit or faulty reverse diode
assembly or gear position switch;
do test D1.
e Neutralindicator does not light, but starter
operates with clutch lever released.
Open circuit to instrument panel bulb,
bulb, or reverse diode assembly.
(cont'd)
3-13
Starting System
— Troubleshooting (cont'd)
TEST A1: Power and Ground Reverse Lever Switch Isolation
1.
Disconnect C92 (reverse lever switch) and with ignition switch ON, check for battery voltage at
BRN/WHT circuit.
If yes, replace reverse lever switch.
If no, service BRN/WHT circuit for an open or short to ground.
TEST A2: Power and Ground isolation
1.
Disconnect C57 (starter/reverse switch) and with ignition switch ON, check for battery voltage at
BLK/LT GRN circuit.
If yes, go to test A3.
If no, go to test A4.
TEST A3: Power and Ground Starter Relay A Isolation
1.
Reconnect C57 and disconnect C41 (starter relay A). With ignition switch ON, check for voltage at
YEL/RED circuit with starter/reverse switch depressed.
If yes, go to step 2.
If no, service YEL/RED circuit for an open. If OK, replace starter/reverse switch.
Check for battery voltage at starter relay A BLK circuit from battery.
If yes, go to step 3.
If no, repair BLK circuit.
With ignition switch ON, gearshift in NEUTRAL, and reverse lever switch in the FORWARD
position, check for voltage between BLK (battery feed) circuit and C41 BRN/RED using a test light.
If yes, go to step 4.
if no, sevice BRN/RED circuit for an open between starter relay A and S302.
Check for battery voltage across BLK circuits at starter relay À.
If yes, go to step 5.
If no, service BLK circuit between starter relay A and 5227 for an open.
Reconnect C41 and disconnect BLK circuits at starter/reverse motor terminal. Connect test light
at starter/reverse motor terminal. With ignition switch ON, reverse lever switch FORWARD and
gearshift in NEUTRAL, press and hold starter/reverse switch. Test lamp should light.
If yes, replace starter/reverse motor.
If no, replace starter relay A.
TEST A4: Power and Ground IGN/Cruise Relay Isolation
1.
Disconnect the iGN/cruise relay. With the ignition switch ON, check for battery voltage at both
WHT circuits.
If yes, go to step 2.
If no, service WHT circuit for an open.
Check for battery voltage between WHT and RED/WHT circuits.
If yes, go to step 3.
If no, go to test AS.
Connect a fused jumper (15A) between WHT and BLK/LT GRN circuit at IGN/cruise relay and
check fo battery voltage at BLK/LT GRN circuit at C57.
If yes, replace IGN/cruise relay.
If no, service BLK/LT GRN circuit.
3-14
ETM
TEST A5: Power and Ground Bank Angle Sensor Isolation
1. Reconnect the IGN/cruise relay. Disconnect C11 (bank angle sensor). Turn the ignition switch ON
and check for battery voltage at RED/WHT circuit.
If yes, go to step 2.
If no, service RED/WHT circuit for an open.
2. Check for battery voltage at WHT circuit.
If yes, go to step 3.
И по, service WHT circuit for an open.
3. Check for battery voltage between WHT and GRN circuits.
If yes, replace bank angle sensor.
If no, service GAN circuit for an open.
TEST B1: Reverse Switch Relay Isolation
1. Disconnect C30 (reverse switch relay). With ignition switch ON and reverse lever switch in
FORWARD, check for battery voltage at YEL/RED circuit.
If yes, go to step 2.
If no, go to test B2.
2. Check for battery voltage at BRN/RED circuit with starter/reverse switch depressed.
If yes, go to step 3.
If no, service BRN/RED circuit for an open.
3. Checkfor battery voltage between YEL/RED and BLK/RED circuits.
If yes, go to step 4.
Ino, check BLK/RED circuit between reverse switch relay and reverse diode assembly for an
open. If OK, replace reverse diode assembly.
4. Check for battery voltage between YEL/RED and BLU/RED circuits.
If yes, go to step 5.
If no, check BLU/RED circuit between reverse switch relay and reverse diode assembly for an
open. If OK, replace reverse diode assembly.
5. With ignition switch ON, gearshift in NEUTRAL, and reverse lever switch in FORWARD, connect a
fused jumper (15A) between BRN/RED circuit at C30 and ground. The starter should crank.
If yes, replace reverse switch relay.
if no, go to test B4.
TEST B2: Reverse Diode Assembly Isolation
1. Disconnect reverse diode assemby connector. With ignition switch ON and reverse lever switch
in FORWARD, check for battery voltage at BLK/WHT (diode D7) circuit.
If yes, go to step 2.
If no, go to test B3.
9. Check for continuity at YEL/RED circuit between reverse diode assembly and reverse switch
relay.
If yes, replace reverse diode assembly.
If no, service YEL/RED circuit.
(cont'd)
3-15
Starting System
— Troubleshooting (cont'd)
TEST B3: Reverse Lever Switch Isolation
1.
Check continuity at BLK/WHT circuit between reverse switch lever and reverse diode assembly.
If yes, replace reverse lever switch.
If no, service BLK/WHT circuit for an open.
TEST B4: Starter Relay B Isolation
1.
Reconnect any components disconnected in previous tests. Disconnect C313 (starter relay B
connector). With ignition switch ON and reverse lever in FORWARD, depress starter/reverse
switch while checking for battery voltage at BLK (starter relay A feed) circuit.
If yes, go to step 2.
if no, service BLK circuit for an open.
Depress starter/reverse switch while checking for battery voltage at YEL/RED circuit.
If yes, go to step 3.
If no, check in-line fuse B, YEL/RED, and RED circuits for an open.
Depress starter/reverse switch while checking for battery voltage between YEL/RED and
GRN/RED circuits.
If yes, go to step 4.
If no, go to test B5.
Jumper the BLK and BLK (with PNK) circuits at starter relay B. With gear selector in NEUTRAL
and reverse lever switch in FORWARD, depress starter/reverse switch. Starter motor should crank.
If yes, replace starter relay B.
it no, service BLK circuit between starter motor and starter relay B for an open.
TEST B5: Reverse Diode Assembly Isolation
1,
Check GRN/RED circuit continuity between starter relay B and reverse diode assembly.
If yes, go to step 2.
If no, service GRN/RED circuit for an open.
With reverse switch in FORWARD, check continuity between GRN/ORN circuit and ground.
If yes, replace reverse diode assembly.
If no, check reverse switch and GRN/ORN circuit.
TEST C1: Clutch Switch Isolation
1.
Disconnect C326 (clutch switch connector). With side stand switch UP check continuity of
GRN/WHT circuit to ground.
If yes, go to step 2.
If no, check GRN/WHT circuit, side stand switch, and GRN circuit at C28 for an open.
Disconnect C325 (clutch switch connector). Check continuity across clutch switch with clutch
lever depressed.
If yes, check GRN/RED circuit for an open. If OK, replace reverse diode assembly.
If no, replace clutch switch.
3-16
ETM
TEST D1: Gear Position Switch Isolation
1. Disconnect C59 (gear position switch) and jumper LT GRN/RED circuit to ground. With side stand
switch DOWN, reverse switch in FORWARD, and ignition switch ON, press starter/reverse switch.
Starter should crank.
if yes, replace gear position switch.
If no, check LT GRN/RED circuit for an open between gear position switch and reverse diode
assembly. If circuit is OK, replace reverse diode assembly.
TEST E1: Power and Ground Isolation
1. Disconnect C57 (starter switch) and with ignition switch ON, check for battery voltage at
BLK/LT GRN circuit.
If yes, go to test E2.
If no, go to test E3.
TEST E2: Power and Ground Starter Relay À Isolation
1. Reconnect C57 and disconnect C41 (starter relay A). With ignition switch ON, check for voltage at
YEL/RED circuit with starter switch depressed.
If yes, go to step 2.
If no, check YEL/RED circuit for an open. If OK, replace starter switch.
2. Check for battery voltage at starter relay A BLK circuit from battery.
If yes, go to step 3.
If no, repair BLK circuit.
3. With ignition switch ON and gearshift in NEUTRAL, check for voltage between BLK (battery feed)
circuit and C41 BRN/RED using a test light.
If yes, go to step 4.
If no, service BRN/RED circuit for an open between starter relay A and S373.
4. Reconnect C41 and disconnect BLK circuit at starter motor terminal. Connect test light at starter
motor terminal. With ignition switch ON and gearshift in NEUTRAL, press and hold starter switch.
Test lamp should light.
If yes, replace starter motor.
If no, check BLK circuit for an open. If OK, replace starter relay A.
TEST E3: Power and Ground IGN Relay Isolation
1. Disconnect the IGN relay. With the ignition switch ON, check for battery voltage at both WHT circuits.
If yes, go to step 2.
if no, service WHT circuit for an open.
2. Check battery voltage between WHT and RED/WHT circuits.
If yes, go to step 3. -
If no, go to test E4.
3. Connect a fused jumper (15A) between WHT and BLK/LT GRN circuit at IGN relay and check for
battery voltage at BLK/LT GRN circuit at C57.
If yes, replace IGN relay.
If no, service BLK/LT GRN circuit.
3-17
Starting System
— Troubleshooting (cont'd)
1.
1.
1.
TEST E4: Power and Ground Bank Angle Sensor Isolation
Reconnect the IGN relay. Disconnect C11 (bank angle sensor). With the ignition switch ON,
check for battery voltage at RED/WHT circuit.
If yes, go to step 2.
If no, service RED/WHT circuit for an open.
Check battery voltage at WHT circuit.
If yes, go to step 3.
If no, service WHT circuit for an open.
Check for battery voltage between WHT and GRN circuits.
If yes, replace bank angie sensor.
If no, service GRN circuit for an open.
TEST F1: Clutch Switch Isolation
Disconnect C325 (clutch switch connector). With side stand switch UP check continuity of
GRN/WHT circuit to ground.
If yes, go to step 2.
If no, check GRN/WHT circuit, side stand switch, and GRN circuit at C28 for an open.
Disconnect C326 (clutch switch connector). Check continuity across clutch switch with clutch
lever depressed.
If yes, check GRN/RED circuit in-line diode C and BRN/RED circuit for an open.
if no, replace clutch switch.
TEST G1: Gear Position Switch Isolation
Disconnect C59 (gear position switch) and jumper LT GRN/RED circuit to ground. With side stand
switch DOWN and ignition switch ON, press starter/reverse switch. Starter should crank.
If yes, replace gear position switch.
if no, check LT GRN/RED circuit in-line diode A and BRN/RED circuit for an open.
3-18
3-19
Charging System
— Circuit Schematic
Y
MAIN
us FUSE B I START DR
7] BATTERY 55A CRUISE FUSE |
— Starting da EE
— System
— S187 @
WHT
See Ground | | RELAY
Distribution, } BOX
page 2-6. i ont |
| | |
© G100 | E 4:10
| CRUISE |
RELAY
| |
ren ere |
See Power ie
Distribution, <— — @ 5251 RELYWHT |
раде 2-0. C32 A cas
WHT BLK/LT GRN RED/WHT | WHT/GRN |
uses IM Жене C11
ith
CB Radio RED/WHT WHT |
Engine
BLK Control == 2 180 S180 ANGLE
IN-LINE System SENSOR
CAPACITOR BLK/LT GRN
B GRN
C11
C43 I
GRN
BLK/LT GRN @ S165
ALTERNATOR B
ue GEN
| IN-LINE
Regulator RAI OR
F E
44 dm] |
3 7 See Ground
= Distribution,
page 2-7.
„|
2 G100
3-20
— How the Circuit Works
The alternator generates an alternating current (AC)
voltage in its windings as it is driven by the engine.
The integral regulator/rectifier converts this AC
voltage into direct current (DC) voltage to maintain
battery charge and operate the electrical system.
When the engine is running, battery voltage is
supplied to the alternator regulator through the
BLK/LT GRN circuit. The alternator then supplies
voltage to the battery and electrical system through
the WHT circuit. Capacitors are connected to each
alternator terminal to reduce alternator electrical
noise.
- Troubleshooting
SYMPTOM
DIAGNOSIS
e Battery is overcharged or undercharged.
Blown main fuse B.
Open WHT circuit to battery; open circuit
to regulator/rectifier or faulty alternator;
do test A.
TEST À : Power and Ground Check
1. Check for battery voltage at alternator terminal B.
If yes, go to step 2.
If no, service WHT circuit for an open.
2. Disconnect C44 (alternator) connector. Turn ignition switch ON and check for battery voltage at
BLK/LT GRN circuit.
If yes, go to step 3.
If no, service BLK/LT GRN circuit for an open.
3. Reconnect C44 and start the engine. Measure voltage across the battery terminals. It should measure
between 13.5 and 15.5 volts.
If yes, perform a battery load test. See service manual, charging section.
If no, service or replace alternator. See service manual, charging section.
3-21
Radiator Fans
— Circuit Schematic
ET =~ 7 FUSE/
| (4) | RELAY
| 4 FUSE |
CF 10A
BLK/BLU
C22
BLU BLU
C109 C110
LEFT 1 RIGHT
NOISE NOISE
FILTER FILTER
LEFT RIGHT
RADIATOR RADIATOR
FAN MOTOR FAN MOTOR
LEFT RIGHT
NOISE NOISE
FILTER FILTER
C109 C110
BLK
BLK
RADIATOR
FAN
TEMPERATURE
SWITCH
= Closes at 98°-102°C
(208-216°F).
3-22
3-23
Reverse System
i Circuit Schematic
| HOT IN ON | | HOT AT ALL TIMES FROM FUSE а |
г UN RT TT IA TT] FUSE/RELAY
TAIL — | BOX
| ION STARTE EAN GE snes EE (MAI N
; CRUISE FUSE RELA
Li ee Na e —————
Г NE OEY EEE NE Ee EE CON GERRARD cms SD ANDES: RENE EEE ;
WH | BRN/BLU
*BAN/WHT | * SE models
GAN s115 e
r | BAN/WHT See Power Distribution,
i See Ground page 2-1.
: Distribution,
WHT | | раде 2-8. T C73
i i 5 |
ee Indicators,
L a ME «т ens ems was smn =Й Aa G100 CONE page 7-0.
BLK/LT GAN = \ y
RED/WHT See Engine 5131 O EX
Control System, — — ан a o = «—
раде 3-0. LE т = = <1 INSTRUMENT
Starting System | © Ground nd LED | PANEL
(Bank Angle Sensor) | | UNIT REVERSE
1 for INDICATOR |
| Bulb Test |
BLK/LT GRN | =p | виа À [5] |
| STARTER/ I = = = == = | COMBINATION WHT/RED WHT/RED To C312 on
| REVERSE | || SWITCH page 3-26.
; SWITCH | Free PUSH || O 5276
| à - | мно | WHT/BLU
VEL/RED WHT/RED Ae
ï C57 ag => @ 5232
YEL/RED
YEL/RED 6 S198 YEL/RED C32 YEL/RED EURE - WHT/BLU
rr ———
YEL/RED Radio/Cassette Deck, WHT/RED WHT/BL
CB Transceiver — fer ven
WHT , See Power | E
Distribution, Во =
age 2-0. Switch Inpu ndicator
BLK я = beg i (System Start
| =" BATTERY | Operation) Starter Relay
| — | one Sl
— eeps starter
Magda = | Ground Relay A on)
| =| REVERSE ESS од
Lid CONTROL E
UNIT GAN ви X C32
To STARTER Solid-state: WHT/BLU
BAN/ RELAY B Do not check LT BLU VHT/BL GO
RED on page 3-26. resistance, ® 5165 HTL C35
Au ЧН LT BLU WHT/BLU N
ee Ground
16 8997 Distribution, | Blanes Solid State
on page 3-26. ‘page 2-7. REGULATOR
See Ground GAN
To REVERSE GAN Distribution, C35
SWITCH RELAY page 2-9.
on page 3-25. BAN/RED rr И, BRN/RED
$302 ® с100 C10
3-24
Revised: May, 1998, 1998 GL1500 ETM
©1998 American Honda Motor Co., Inc. — All Rights Reserved
MSV 8022 (9803)
ETM
| Hormon | ON
Te FUSE/RELAY
©) | BOX
RVS START |
FUSE |
5A }
dis dm is ms aa
pa
BRN/WHT
C92
BRN/WHT
REVERSE
LEVER
REVERSE FORWARD SWITCH
WHT/ BLK/
BLU \ WHT
se C92
WHT BLK/WHT C32 (a
S303 @
Reverse | i GONTHOL
Rela
| Switch Solid-state:
| Output | Side | Do not check
| (Energizes relay for Engine Stand | resistance.
| 1 second Monitor Switch
then deenergizes) Input Input
| |
rama ON (— С42
BLU/RED
C32
ZE neo BLU/RED
S250 © [email protected] Indicators
|
C22
YEL/RED BLU/RED
PRE SSURE
PRE
DIODE SWITCH
ASSEMBLY Open above
| «ты «т — к 1-3 psi
| YEL/RED (0.1-0.2 kg/em?).
A === @® 5310
L J From S302
VEL/RED on page 3-24.
GRN/WHT
C32
T0 Y INSTRUMENT
YEL/RED | BRN/RED
— — — — C30
3 den | PANEL REVERSE
SWITCH
| (©) INDICATOR | ph
| N] | From STARTER RELAY B
LT GRN/RED ee BLK/RED — hos
LT orne GRN/RED BLK/RED BLU/RED
CSS can E ; > - “1 REVERSE Е
trol
LT GAN 3 ( RED k I | DIODE on
| ASSEM- System
ne N D1 ра Y D6 T D3 D2 an
в é
| Neutral | CONTROL E WHT
Switch | UNIT
Input Solid-stat . GRN/WHT
GRN/ORN i olid-state:
L. Ye — 4 Do not check Re
Ca2 resistance. Ya S257
LT GRN/RED y CONTI
LT GRN/RED
C32 5306 ® C28
\ LT GRN/RED GRN/WHT
GRN/ORN À C32 г un SIDE _
-—
LT GRN/RED |
| Ä Г. GRN/RED Engine | UP \DOWN y SWITCH
\ S186 @ Control E a ll
LT GAN/RED System GRN C28
\ C59 GRN y
EE T СЕАВ eur
2 | POSITION istribution,
REVERSE | Nk a SWITCH i page 2-8.
SWITCH | € a |
Open in Г | 2 G100
reverse. EE EEN"
- = (cont'd)
3-25
Reverse System
— Circuit Schematic (cont'd)
From S232
оп раде 3-24.
WHT/BLU es
C312
WHT/BLU
WHT/BLU
RED
—
WHT
s304 8 —
WHT/BLU
WHT
WHT WHT
From STARTER RELAY A on
page 3-24,
BLK |
5227
| POWER
CONTROL
RELAY
al #1
RED
YEL/RED
C316
From STARTER RELAY A on
SPEED
LIMITER
RELAY
oa i N Es
page 3-24.
REVERSE
RESISTORS
GRY
NN ————— — C312
WHT | GRY : ORN |
aaa — C32
WHT L GRY ORN
EL Te te re pa
9 e “e 1 |
: PC? Ground SA PON |
Output for Reverse Output Output i
| Control Indicator Control Control |
| Signal Te E rm ; |
Caz
ve C312 ye; 092 E
S307 € (ga
YEL
SPEED — BATTERY
LIMITER
See Ground
Distribution,
i page 2-6.
2 G100
Tal
PNK
STARTER
RELAY
B
C31 3
GRN/RED 1
C32
GRN/RED
C29
REVERSE «||
CONTROL G32
UNIT To REVERSE PNK
DIODE ASSEMBLY IN-LINE
on page 3-25. FUSEA
5A
PNK/ \
WHT \
C32
BLK
PNK
С42
REVERSE F=" 7377
CONTROL | Monitors
STARTER/ UNIT ‘Motor
REVERSE Voltage |
MOTOR
3-26
ETM
- How the Circuit Works
The reverse control unit takes a series of inputs from
external switches and also monitors voltage
developed at the starter/reverse motor to determine
what outputs should be controlled to make reverse
direction possible.
When the reverse lever switch is in the REVERSE
position, battery voltage is applied to pin 3
(WHT/BLU) and ground is provided on pin 1 (GRN)
from G100.
System Check
If power and ground are OK, the reverse control unit
then starts a system check to look for the following:
e Battery voltage applied to pin 5 (BLU/RED) when
the engine is started and oil pressure is above
1-3 psi.
e Ground present at pin 8 (LT GRN/RED) whenthe
gearshift sensor is in NEUTRAL.
e Ground present at pin 10 (GRN/WHT) when the
side stand switch is in the UP position.
e Ground present on pin 12 (YEL), providing a
ground for the reverse indicator and to establish
that the speed limiter fuse is good.
When the reverse indicator has been illuminated, the
driver knows the system is ready for operation. The
driver presses the starter/reverse switch and battery
voltage is applied to pin 11 (YEL/RED) of the reverse
control unit. As this input is received, a set of outputs
starts controlling other system components.
e The reverse control unit provides 9 volts for one
second on pin 14 (YEL/RED) to briefiy energize
the reverse relay switch. The reverse relay switch
contacts close to provide a one second path to
ground. This pulis the contacts of starter relay À
closed.
e Atthe same time that pin 14 outputs to the
reverse relay switch, the reverse control unit
grounds pin 7 (LT BLU), which grounds the
starter relay regulator. This provides the hold-in
current path (BRN/RED) to keep the contacts of
starter relay A closed while the starter/reverse
switch is pushed.
e Pin 6 (ORN) is grounded by the reverse contro!
unit when the starter/reverse switch is pushed
and minimum load is applied to the motor.
e Pin 9 (WHT) is grounded when maximum load is
applied to the motor.
System Reset
System reset is required when vehicle speed
exceeds 2.5 km/h or when the starter/reverse motor
has experienced an electrical motor brake of three
seconds or more. The reverse control unit monitors
the starter/reverse motors voltage, and if it
determines an excessive speed, it grounds pin 2
(GRY), allowing the speed limiter relay's contacts to
close. This removes some of the voltage to the
starter/reverse motor.
If it determines an electrical motor brake, then the
control unit removes all power to the starter/reverse
motor by de-energizing starter relay A. The reverse
control unit also provides battery voltage to pin 4
(WHT/RED), turning the reverse indicator off. Before
the system may be operated again, the reverse lever
switch must be recycled back to the forward
position, applying battery voltage to pin 14
(YEL/RED).
3-27
Reverse System
- Troubleshooting
SYMPTOM
DIAGNOSIS
Reverse system doesn’t operate and the
reverse indicator doesn't light.
No power to reverse control unit;
do self-test A, pin 3.
No ground to control module;
do self-test B, pin 1,
Bad side stand switch input;
do self-test B, pin 10.
No neutral position input from gearshift
sensor, do self-test B, pin 8.
Incorrect oil pressure switch input;
do self-test A, pin 5.
Bad speed limiter fuse (65A);
do self-test B, pin 12.
Faulty reverse control unit. Replace with
known good reverse control unit.
Reverse system operates for only a few
seconds, then quits. Reverse indicator
turns off or reverse system doesn't
operate and the reverse indicator lights.
No voltage to starter/reverse motor;
do self-test A, pin 13.
No control signal to reverse control unit
from starter/reverse switch;
do self-test À, pin 11.
No control signal from reverse control unit
to reverse relay switch;
do self-test A, pin 14.
No control signal from reverse control unit
to starter relay regulator;
do self-test A, pin 7.
3-28
ETM
SYMPTOM
DIAGNOSIS
Reverse system operates, but very slowly
or no power on inclines.
Faulty control signal from reverse control
unit to power relay control #1;
do self-test A pin 6.
Faulty control signal from reverse control
unit to power relay control #2;
co self-test A pin 9.
Inoperative power relays; do self-test Е.
If all the above are OK, check red circuits
to power relay controls for battery voltage
with ignition ON, starter reverse switch in
REVERSE, and the starter/reverse switch
pushed. If voltage is not present, service
circuits for an open.
Reverse system operates above 2.5 km/h
down inclines.
inoperative speed limiter relay;
do self-test A pin 2.
Reverse system operates, but reverse
indicator doesn’t light.
No control signal from reverse control unit
indicator; do self-test À pin 4.
(cont'd)
3-29
Reverse System
rm Troubleshooting (cont'd)
SELF-TEST A: Static Measurements
Note: Leave C42 connected to reverse control unit.
Make all measurements between pin # given in domestic table and ground (pin #1).
Starter Reverse Motor Input (PNK) Starter Relay Regulator Output (LT BLU)
Varying voltage present with ignition Voltage drops from 1.5 volts to 0 volts with
switch in ON, reverse lever switch in the engine running, reverse lever switch in
REVERSE and starter reverse switch REVERSE and the starter/reverse switch
pushed. i | pushed.
If not, check in-line fuse A (5 amp). If not, replace the reverse control unit.
If fuse is good, check circuit for an open.
If all measurements are good,
do self-test A pin 11. C42
(HARNESS SIDE)
aris Oil Pressure Switch Input (BLU/RED)
—> 13/10 0 volts with ignition switch ON.
SN Па: If not, check to see if oil pressure
Г” 6 | 7 | indicator operates.
) If so, service BLU/RED circuit for an open.
Power Relay Control #1 Output (ORN) ; la PE
Battery voltage with ignition switch ON Ве sp daba! ig
and reverse lever switch in REVERSE. 5 |=
If not, replace reverse control unit. | =
Lightly apply rear brake. Voltage should AL
drop .5 volts. If not, replace reverse = Reverse Indicator Output (WHT/RED)
control unit. 1 9 | with ignition ÓN, see if indicator
If both measurements are correct, 12| 2 lo illuminates for bulb test.
go to self-test F. ; O volts present with the reverse system in
11/14 operation.
Е If not, replace the reverse control unit.
If so, short WHT/RED circuit to ground
and if indicator dosen't illuminate,
service WHT/RED circuit for an open.
4
Starter/Reverse Switch Input (YEL/RED)
Battery voltage with ignition switch ON
and starter/reverse switch depressed.
If not, service YEL/RED circuit for an open.
If measurements are correct, go to the
next diagnostic step.
Reverse Lever Switch Input (WHT/BLU)
— Battery voltage with ignition switch ON
and reverse lever switch in REVERSE.
If not, do self-test C.
Speed Limiter Relay Control (GRY)
Reverse Relay Switch Input/Output Battery voltage with ignition switch ON,
(YEL/RED) reverse lever switch in REVERSE and
Battery voltage with reverse lever switch starter/ reverse switch pushed.
in FORWARD. If not, replace reverse control unit.
If not, do self-test C. _ | Push cycle on level ground to exceed 2.5
9 volts for approximately 1 second with km/h while in reverse operation; voltage
starter reverse switch pushed. will drop to below .5 volts.
If not, replace control unit. If not, replace reverse control unit.
If all measurements are correct, If all measurements are correct,
service YEL/RED circuit for an open. go to self-test G.
3-30
SELF-TEST B: Continuity Test
Note: Disconnect C42 from reverse control unit.
Make measurements between G100 (terminal) and desired pin on connector C42.
Speed Limiter Fuse (65 amp) Input
(YEL)
Check for continuity to ground G100.
If bad, check speed limiter fuse
(65 amp).
If good, check (YEL) or (BLK) circuit
for an open.
If all measurements are good,
go to the next diagnostic step.
C42
(TERMINAL SIDE)
11| 14
12 , 2
Ground Input (GRN)
Check for continuity to ground G100.
If there is no continuity, repair GRN
circuit for an open.
If OK, go to the next diagnostic step.
Power Relay Control #2 Output
(WHT)
Battery voltage with ignition switch
ON and reverse lever switch in
REVERSE.
If not, replace reverse control unit.
Fully apply rear brake. Voltage
should drop below .5 volts.
If not, replace reverse control unit.
If both measurements are correct,
do self-test F.
3
4
INE
9
7
Neutral Switch Input (LT GRN/RED)
With transmission in neutral, check
for continuity to ground.
If not, check LT GRN/RED circuit for
an open.
If OK, see if neutral indicator
illuminates in bulb test and then
stays illuminated.
If bulb doesn’t light during bulb test,
replace bulb.
If bulb only lights for bulb test,
do self-test E.
13/10
Side Stand Switch Input (GRN/WHT)
With side stand in UP continuity
should exist to ground G100.
If not, check GRY/WHT circuit for
an open.
If OK, go to self-test D.
(cont'd)
3-31
Reverse System
~ Troubleshooting (cont'd)
SELF-TEST C: Reverse Lever Switch
Note: Consult service manual for mechanical operations and alignment.
1.
4.
With transmission in NEUTRAL and reverse lever switch in FORWARD,
see If the neutral indicator lights.
If yes, go to step 3.
If no, go to the next step.
Check for battery voltage at BRN/WHT circuit of reverse lever switch connector C92.
If yes, go to the next step.
If no, service BRN/WHT circuit for an open.
With C92 disconnected, check continuity between:
e BRN and BLK/WHT circuits with reverse lever switch in FORWARD
e BRN and WHT/BLU circuits with reverse lever switch in REVERSE
If no continuity exists, replace reverse lever switch.
If all measurements are OK, go to the next step.
Service WHT/BLU circuit for an open.
SELF-TEST D: Side Stand Switch
1.
With the ignition ON and side stand DOWN, check to see if side stand indicator lights.
If yes, go to step 3.
If no, go to the next step.
With C28 disconnected, check for continuity between GRN circuit and ground G100.
If yes, go to the next step.
If no, service GRN circuit for an open.
Disconnect C28 and check continuity between GRN/WHT and GRN circuits on switch side of
connector with side stand switch DOWN.
If yes, go to the next step.
If no, replace side stand switch.
With C28 still disconnected, check continuity between YEL/BLK and GRN circuits.
If no, replace side stand switch.
SELF-TEST E: Gear Position Switch Test
1.
Disconnect C59. With the transmission in NEUTRAL, check continuity between LT GRN/RED
circuit and ground.
If not, replace the gear position switch.
3-32
SELF-TEST F: Power Relay Control Test
With suspected relay disconnected, apply 12 volts across coil and measure continuity
across contacts.
e Power relay control #1 — continuity exists
e Power relay control #2 — continuity does not exist
if incorrect, replace relay.
If OK, go to next step.
2. Power relay control #1; check continuity of BLK circuit from contacts and repair if necessary.
Power relay control #2; check continuity of WHT circuit from contacts and repair if necessary.
If all measurements are OK, go to self-test H.
SELF-TEST G: Speed Limiter Relay Test
1. With relay disconnected, apply 12 volts across the coil and measure continuity across
contacts; continuity should exist.
If not, replace speed limiter relay.
If OK, go to next step.
2. Check continuity of WHT circuit and YEL circuit from contacts and repair if necessary.
If OK, go to self-test H.
SELF-TEST H: Reverse Resistors
1. Disconnect starter/reverse motor terminal connector from reverse resistors.
2. Disconnect connector C316 and measure between all wires and terminal from previous step.
3. if resistance is above 2 ohms for any measurement, replace reverse resistors.
3-33
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement