18. LIGHTS/METERS/ SERVICE INFORMATION TROUBLESHOOTING SWITCHES XL200

Transcription

1 XL LIGHTS/METERS/ SWITCHES SERVICE INFORMATION 18-1 TROUBLESHOOTING 18-1 HEADLIGHT 18-2 TAIL/BRAKE LIGHT 18-3 TURN SIGNAL LIGHT 18-3 COMBINATION METER 18-4 IGNITION SWITCH 18-6 HANDLEBAR SWITCH 18-6 BRAKE LIGHT SWITCH 18-7 CLUTCH SWITCH 18-8 HORN 18-8 SERVICE INFORMATION GENERAL All electrical wires and connectors are color-coded. When two or more different colored wires are connected, a colored tube that matches the major color of the other wire appears on the wire near the connector. Observe the color codes before disconnecting ant wires. All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. In order to isolate the electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the part from the motorcycle by simply disconnecting the wires and connecting a continuity tester or ohmmeter to the terminals or connections. SPECIFICATIONS ITEM Headlight 12 V 35/35 W Tail/stop light 12 V 5/21 W Turn signal light 12 V 10 W x 4 Instrument light 12 V 3.4 W High beam indicator 12 V 1.7 W Neutral indicator 12 V 3.4 W Turn signal indicator 12 V 3.4 W Fuse 15 V SPECIFICATIONS TROUBLESHOOTING No lights when the engine is running and lighting switch is ON Faulty bulb Faulty switch Broken leads Miswiring Lights come on, but only dimly Faulty alternator Wiring or switch has excessive resistance Faulty regulator/rectifier

2 LIGHTS/METERS/SWITCHES XL

3 LIGHTS/METERS/SWITCHES XL200 HEADLIGHT BOLT BULB REPLACEMENT Remove the bolts and front fairing. FAIRING Remove the headlight socket. SOCKET Remove the dust seal and unhook the retainer. RETAINER Remove the bulb and replace with a new one. BULB Installation is in the reverse order of removal. 18-2

4 XL200 UNIT REPLACEMENT LIGHTS/METERS/SWITCHES SCREWS Remove the headlight beam adjusting screw. Remove the bracket screw, then remove the headlight unit. Installation is in the reverse order of removal. TAIL/BRAKE LIGHT BULB REPLACEMENT Remove the screws and tail/brake light lens. Push the brake light bulb in, turn it counterclockwise and remove it. Pull out the tail light bulb and remove it. Install the bulb in the reverse order of removal. TURN SIGNAL LIGHT LENS BULB REPLACEMENT Remove the screw and turn signal lens. SCREW 18-3

5 LIGHTS/METERS/SWITCHES XL200 Push the bulb in, turn it counterclockwise and remove it. BULB Install the bulb in the reverse order of removal. TURN SIGNAL RELAY INSPECTION If the turn signals do not work properly, check for the following items: battery conditions burned lamp lamp incorrect voltage loose connectors If the items listed above do not show any problems, proceed as follows: Disconnect the turn signal conector and short it with an auxiliary wire. Turn the ignition switch and check the turn signal operation. The turn signals do not work Short or open circuit in the main wiring The turn signals light on Faulty turn signal relay Loose conector COMBINATION METER BULB SOCKET BULB REPLACEMENT Remove the meter bulb sockets and replace the bulb if necessary. 18-4

6 XL200 LIGHTS/METERS/SWITCHES REMOVAL Remove the combination meter 6P connector. Remove the combination meter bulb sockets from the combination meter, then remove the sub-harness. Disconnect the speedometer and tachometer cable. Remove the cap nuts, washers and combination meter assembly. BULB SOCKET DISASSEMBLY Remove the screws, wire clamp and combination meter upper cover. Remove the trip meter knob, then remove the speedometer. ASSEMBLY Assemble the combination meter in the reverse order of removal. 18-5

7 LIGHTS/METERS/SWITCHES XL200 IGNITION SWITCH INSPECTION Disconnect the ignition switch wire connector. Check for continuity between each terminal. There should be continuity between the circuit marked O-O in the tables below. IGN E BAT BA1 OFF O O ON O O COLOR B/W G B R REMOVAL Disconnect the ignition switch wire connector. Remove the mounting bolts and ignition switch. Install the ignition switch in the reverse order of removal. NOTE Apply a locking agent to the ignition switch bolt threads. HANDLEBAR SWITCH Disconnect the handlebar switch wire connectors. 18-6

8 XL200 LIGHTS/METERS/SWITCHES Check for continuity between each terminals. There should be continuity between the circuit marked O-O in the tables below. See section 12 for removal. Lighting, dimmer switch LIGHTING SWITCH DIMMER SWITCH Lighting Dimmer HL BAT TL HL HI LO Lo O O (N) O O (N) O O O H O O O Hi O O Color B Br Color L W Horn switch TURN SIGNAL SWITCH HORN SWITCH ENGINE STOP SWITCH HO BAT Free Push O O Color Lg Bl Turn signal switch WR R L L O O N R O O Color GR SB O BRAKE LIGHT SWITCH FRONT STARTER SWITCH Disconnect the front brake light switch wire connectors. There should be continuity with the brake lever is squeezed. There should be no continuity with the brake lever is released. CONNECTOR REAR CONNECTOR Remove the left side cover. Disconnect the rear brake light switch 2P connector. There should be continuity with the brake pedal is depressed. There should be no continuity with the brake pedal is released. REAR BRAKE LIGHT SWITCH 18-7

9 LIGHTS/METERS/SWITCHES XL200 CLUTCH SWITCH CONNECTOR Disconnect the brake light switch wire connectors. There should be continuity with the brake lever is squeezed. There should be no continuity with the brake lever is released. CLUTCH SWITCH HORN Disconnect the horn wire connectors and connect a fully charged 12V battery to the horn terminals. The horn is normal if it sounds when the battery is connected across the terminals. Horn does not sound, check the ignition switch and horn switch. If both switch normal, check for open or short circuit in light green wire and green wire. (1) HORN (2) BATTERY 18-8

10 XL200 LIGHTS/METERS/SWITCHES NOTES 18-9

11 GENERAL INFORMATION HOW TO USE THIS MANUAL This service manual describes the service procedure for the XL200. Throughout the manual, the following abbreviations are used to identify individual models. Code DK 2LA Area (type) General Type Latin America Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operation condition. CONTENTS GENERAL INFORMATION 1 LUBRICATION 2 MAINTENANCE 3 FUEL SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Section 1 through 3 apply to the whole motorcycle, while section 4 through 18 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section, the subsequent pages give detailed procedures. If you don t know the source of the trouble, go to section 20 TROUBLESHOOTING. All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing. MOTO HONDA DA AMAZÔNIA LTDA. Reserves the right to make changes at any time without notice and without incurring any oblication whatever. Not part of this publication may be reproduced without written permission. ELECTRIC STARTER FRAME ENGINE CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 CLUTCH/GEARSHIFT LINKAGE 8 ALTERNATOR/STARTER CLUTCH 9 CRANKSHAFT/KICKSTARTER/ TRANSMISSION 10 FRONT WHEEL/SUSPENSION/STEERING 11 REAR WHEEL/SUSPENSION 12 HYDRAULIC BRAKE 13 FAIRING/EXHAUST SYSTEM 14 CHARGING SYSTEM 15 IGNITION SYSTEM 16 ELECTRIC STARTER 17 LIGHTS/METERS/SWITCHES 18 WIRING DIAGRAM 19 TROUBLESHOOTING 20