Kymco MO D50 Service Manual - chap 19 (interruttori strumentazione luci)

Page 1
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-0
19
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
SWITCHES/HORN/FUEL UNIT/THERMOSTATIC
__________________________________________________________________________________
ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5 THERMOSTATIC SWITCH ------------------------------------------- 19-6 TEMPERATURE GAUGE --------------------------------------------- 19-6 INSTRUMENTS--------------------------------------------------------- 19-7 LIGHTS ------------------------------------------------------------------ 19-8
19
Page 2
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-1
ELECTRICAL EQUIPMENT LAYOUT
Fuel Unit
Starter Button
Horn
Ignition Switch
Auto Bystarter
Thermosensor
Turn Signal Switch
Stop Switches
Horn Button
Headlight Dimmer Switch
Instruments
Headlight Switch
Page 3
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
After installation of each switch, a continuity check must be performed. A continuity check can
usually be made without removing the part from the motorcycle.
TESTING INSTRUMENT
Electric tester
SPECIAL TOOL
Fuel unit wrench
TROUBLESHOOTING
Lights do not come on when ignition Temperature gauge does not register switch is “ON” correctly
Burned bulb Faulty temperature gauge
Faulty switch Faulty thermosensor
Poorly connected, broken or shorted wire Broken or shorted wire between
temperature gauge and thermosensor
Fuel gauge pointer does not move or register correctly
Faulty fuel gauge
Faulty fuel unit
Poorly connected wire between fuel
gauge and fuel unit
Fuse burned out
SPECIFICATIONS
Fuse 20A Headlight bulb 12V 35W/35W Turn signal light bulb 12V 10W Stoplight/taillight 12V 5W License plate light 12V 3.4W Instrument light 12V 1.7W Position light 12V 3W/5W Turn signal indicator light 12V 10W
Page 4
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-3
SWITCHES
IGNITION SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals.
Color
Position
R
B/WGB
LOCK
OFF
ON○○
HEADLIGHT SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the headlight switch wire couplers. Check for continuity between the wire terminals.
Color
Position
Y
BR/W
BR
L/W
P
P
○○○
H
○○○
STARTER SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the starter switch wire couplers. Depress the starter button and check for continuity between the wire terminals.
Color
Position
Y/R
G
FREE
PUSH
PASSING SWITCH
Remove the front upper cover. (2-5) Disconnect the headlight switch wire couplers. Check for continuity between the passing switch wire terminals.
Color
Position
L
L/W
FREE
PUSH
Passing Switch
Ignition Switch
Headlight Switch G
B
B/W
G
R
BR
Y
L/W P
G
Y/R
L
L/W
Starter Switch
Passing
Page 5
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-4
HORN BUTTON INSPECTION
Remove the frame front covers. (2-5) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals.
Color
Position
LG
BR/L
FREE
PUSH
TURN SIGNAL SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the turn signal switch wire couplers and turn on the turn signal switch. Check for continuity between the wire terminals.
Color
Position
SBOGR
L
N
R
DIMMER SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the headlight dimmer switch wire couplers. Turn on the dimmer switch and check for continuity between the wire terminals.
Color
Position
L/W
L
W
LO
N○○
HI
STOP SWITCH INSPECTION
Remove the frame front covers. (2-5) Disconnect the front/rear stop switch wire couplers. Check for continuity between the wire terminals when the front brake lever is applied.
Color
Position
BR/L
G/Y
FREE
APPLY
Horn Button
Turn Signal Switch
Dimmer Switch
Stop Switch BR/L
G/Y
W
L/W L
SBOGR
LG BR/L
Page 6
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-5
HORN INSPECTION
Remove the front upper cover. (2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
FUEL UNIT
FUEL UNIT INSPECTION
Remove the fuel unit. Disconnect the fuel unit wire connectors. Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions.
Wire Terminals
Upper
Lower
Y/W_ G
33_ 45Ω
500_ 850Ω
L/W_ G
400_ 700Ω
100_ 200Ω
Y/W_ L/W
450_ 750Ω
450_ 750Ω
FUEL GAUGE INSPECTION
Connect the fuel unit wire connectors and turn the ignition switch “ON”.
Check the fuel gauge needle for correct indication by moving the fuel unit float up and down.
Float Position
Needle Position
Upper
“F” (Full)
Lower
“E” (Empty)
Wire Terminals
Needle Position
Y/W_ G
From E to F
L/W_ G
From F to E
The fuel gauge is normal if it operates as above indicated. If not, check for loosely tightened nuts, poorly connected terminals or shorted wires.
Fuel Unit
Before performing the following test, operate the turn signals to determine that the battery circuit is normal.
Horn
12V Battery
Lower
Upper
Lower
Upper
Upper
Fuel Gauge
Lower
Needle moves from F to E.
Page 7
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-6
OIL METER
INSPECTION
Remove the met-in box. (2-4) Remove the frame body cover. (2-4) Disconnect the oil meter wire connectors and remove the oil meter. Keep the oil meter float at the lower position. Measure the resistances between the wire terminals as  and  shown in the left figure.
Wire Terminals
Resistance
Green/Red(+)_ Black(-)
5_ 16Ω
Green(-)_ Black(+)
Oil Meter Operation Inspection
Connect the oil meter wire connectors and turn the ignition switch ON. Measure the resistance between the wire terminals with the float at upper position.
Green/Red(+)_ Black(-)
About 340Ω
TEMPERATURE GAUGE
Disconnect the wire from the thermosensor and ground it to the engine. Turn the ignition switch ON. The temperature gauge needle should move all the way to “H”.
Do not leave the thermosensor wire grounded for longer than 5 seconds or the temperature gauge will be damaged.
Before performing the following test, operate the turn signals to determine that the battery circuit is normal.
Before removing the oil meter, be sure to drain the motor oil and do not allow sparks or flames near the working area.
Light OFF
Light ON
Oil Meter
Float
G/RBB
G
G
Page 8
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-7
INSTRUMENTS
REMOVAL
Remove the front upper cover. (2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable.
Remove the four instrument cover and leg shield screws. Remove the two instrument holder bolts. Remove the instruments.
DISASSEMBLY/ASSEMBLY
Remove the three instrument holder nuts. Remove the holder. Remove the four screws to disassemble the instruments and instrument cover . Assemble the instruments in the reverse order of disassembly.
INSTALLATION
The installation sequence is the reverse of removal.
Wire Couplers
Speedometer Cable
Screws
Holder Bolts
Screws
Screws
Page 9
19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS
19-8
LIGHTS
HEADLIGHT BULB REPLACEMENT
Remove the front upper cover. (2-5) Disconnect the headlight and turn signal light wire couplers. Remove the rubber boot from the bulb socket. Remove the bulb socket and replace the bulb. Install the bulb socket, aligning the bulb socket tab with the groove. Install the rubber boot. Install the front cover in the reverse order of removal.
FRONT POSITION LIGHT BULB REPLACEMENT
Remove the front upper cover. (2-5) Disconnect the headlight and turn signal light wire couplers. Remove the bulb sockets by turning them counterclockwise. Remove the bulbs and replace them with new ones.
FRONT TURN SIGNAL LIGHT BULB REPLACEMENT
Remove the two screws attaching the turn signal light shell and remove the light shell. Remove the bulb and replace with a new one.
TAILLIGHT/REAR TURN SIGNAL LIGHT BULB REPLACEMENT
Remove the rear protective cover. (2-3) Remove the two screws attaching the rear light shell and remove the light shell. Remove the bulbs and replace with new ones. The installation sequence is the reverse of removal.
Screws
Front Position Light Bulb Sockets
Wire
Bulb Socket
Screws
Wire
Loading...