Check and replacementSk

Check

1 Before checking the switches, and if not already done, check the brake light circuit (see Section 6, Steps 8 and 9).

2 The front brake light switch is mounted on the underside of the brake master cylinder. Disconnect the wiring connectors from the switch (see illustration) Using a continuity tester, connect the probes to the terminals of the switch. With the brake lever at rest, there should be no continuity. With the brake lever applied, there should be continuity. If the switch does not behave as described, replace It with a new one.

13.7 Rear turn signal wiring connectors -XL650V

13.8a Rear turn signa! nut (arrowed) -XL600V

14.2 Front brake switch wiring connectors 14.3 Rear brake light switch (arrowed) (arrowed)

3 The rear brake light switch is mounted on the inside of the frame, above the brake pedal and just ahead of the master cylinder (see illustration). Remove the seat and if necessary the right-hand side panel to access the wiring connector (see Chapter 8), Trace the wiring from the switch and disconnect it at the connector. Using a continuity tester, connect the probes to the terminals on the switch side of the wiring connector. With the brake pedal at rest, there should be no continuity. With the brake pedal applied, there should be continuity. If the switch does not behave as described, replace it with a new one, although check first that it is correctly adjusted (see Step 10).

4 If the switches are good, check for voltage at the black wire terminal on the connector with the ignition switch ON - there should be battery voltage. If there's no voltage present, check the wiring between the switch and the ignition switch via the fusebox (see the Wiring Diagrams at the end of this Chapter). II voltage is present, check the green/yellow wire for continuity to the brake light bulb wiring connector, referring to the relevant Wiring Diagram. Repair or renew the wiring as necessary.

Replacement

Front brake lever switch

5 The switch is mounted on the underside of the brake master cylinder. Disconnect the wiring connectors from the switch (see illustration 14.2).

6 Remove the single screw securing the switch to the master cylinder and remove the switch, noting how it fits.

7 Installation is the reverse of removal. The switch isn't adjustable.

Rear brake pedal switch

8 The rear brake light switch is mounted on the inside of the frame, above the brake pedal and just ahead of the master (see illustration 14.3). Remove the seat and if necessary the right-hand side panel to access the wiring connector (see Chapter 8). Trace the wiring from the switch and disconnect it at the connector.

9 Detach the lower end of the switch spring from the brake pedal, then either release the switch with its adjustment nut from the mounting by squeezing the tabs on the underside of the nut. or thread the switch itself out of the nut. leaving the nut in the mounting.

10 Installation is the reverse of removal. Make sure the brake light is activated just before the rear brake pedal takes effect. If adjustment is necessary, hold the switch body and turn the adjustment nut as required (either raising or lowering the switch) until the brake light is activated correctly.

15.2 Unscrew the retaining ring (arrowed) 15.3a Instrument cluster wiring 15.3b Instrument cluster wiring and detach the cable connectors - XL600V connectors - XL650V

15.2 Unscrew the retaining ring (arrowed) 15.3a Instrument cluster wiring 15.3b Instrument cluster wiring and detach the cable connectors - XL600V connectors - XL650V

15.4a Unscrew the nuts (arrowed)... 15.4b ... and remove the instrument cluster

15 Instrument cluster and speedometer cable - ^

removal and installation ^

Instrument cluster - XL models

1 Remove the fairing (see Chapter 8).

2 Unscrew the knurled ring securing the speedometer cable in the instrument cluster and detach the cable, noting how it fits (see illustration).

3 Trace the wiring from the cluster and disconnect It at the connectors (see illustrations).

15.11a Disconnect the wiring connectors .. -

4 On XL600V models, unscrew the three nuts, noting the washers where fitted, and remove the instrument cluster, noting how it fits (see illustrations).

5 On XL650V models, unscrew the four bolts, noting the collars, and remove the instrument cluster, noting how it fits.

6 Installation is the reverse of removal. Check the rubber grommets for damage, deformation and deterioration and replace them with new ones if necessary. Make sure that the wiring connectors are correctly routed and secured.

Instrument cluster ~ XRV750-L and M models

7 To access the instrument cluster first remove the fairing (see Chapter 8).

8 The instrument cluster comes in two pieces, one for the speedometer and warning light assembly, the other for the tachometer and temperature gauge. Each is secured by three nuts. If removing the speedometer assembly, unscrew the knurled ring securing the speedometer cable in the instrument cluster and detach the cable, noting how it fits. Disconnect the relevant wiring connectors, then unscrew the relevant nuts, noting the collars, and draw the instrument cluster off the studs, noting how it fits.

9 Installation is the reverse of removal. Check the rubber grommets for damage, deformation and deterioration and replace them with new ones if necessary. Make sure that the wiring connectors are correctly routed and secured.

Instrument cluster -XRV750-N models onwards

10 To access the instrument cluster first remove the fairing (see Chapter 8). To access the digital trip meter remove the windshield (see Chapter 8).

11 Trace the wiring from the cluster and disconnect it at the connectors (see illustration). Unscrew the four bolts, noting the collars, then displace the instrument

15.11b ... then unscrew the bolts and remove the collars

15.11c Displace the cluster and unscrew the speedometer cable retaining ring (arrowed)

15.12 Disconnect the wiring connector (A), then unscrew the nuts (B)

15.20a Locate the drive tab in the slot in the cable end . . .

15.20b ... then secure the cable with the screw

15.18 Make sure the hole in the guide locates over the pin (arrow)

15,16 Undo the screw (arrowed) and detach the cable

15.17 Slacken the screw (arrowed) and free the cable from the guide

15.20a Locate the drive tab in the slot in the cable end . . .

15.20b ... then secure the cable with the screw

15.18 Make sure the hole in the guide locates over the pin (arrow)

15.11c Displace the cluster and unscrew the speedometer cable retaining ring (arrowed)

(see illustration). Withdraw the cable from the motorcycle, noting its routing. Installation

18 Route the cable correctly between the instrument cluster and the front wheel and secure it in the guides and ties (see illustration).

19 Connect the cable upper end to the instrument cluster and tighten the knurled ring securely (see illustration 15.2 or 15.11c)

20 Fit the lower end of the cable Into the drive housing on the right-hand side of the front wheel, aligning the slot in the cable end with the drive tab. and secure it with its screw (see illustrations)

21 Check that the cable doesn't restrict steering movement or interfere with any other components.

16 Instruments -

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