Motorcycle Headlight And Sidelight Wiring

Always use a paper towel or dry cloth when handling new bulbs to prevent injury if the bulb should break and to increase bulb life.

7.1a Disconnect the wiring connector ...

7 Headlight bulbs and sidelight bulbs - renewal

Note: The headlight bulbs are of the quartz-halogen type. Do not touch the bulb glass as skin acids will shorten the bulb's service life. If the bulb is accidentally touched, it should be wiped carefully when cold with a rag soaked in methylated spirit and dried before fitting.

A Warning: Allow the bulbs time to cool before removing them if the headlight has just been on.

Headlight

1 Disconnect the relevant wiring connector from the back of the headlight assembly and

7.1b ... and remove the dust cover remove the rubber dust cover, noting how it fits (see illustrations).

2 Release the bulb retaining clip, noting how it fits, then remove the bulb (see illustrations).

3 Fit the new bulb, bearing in mind the information in the Note above. Make sure the tabs on the bulb fit correctly in the slots in the bulb housing, and secure it in position with the retaining clip.

4 Install the dust cover, making sure it is correctly seated and with the 'TOP' mark at the top, and connect the wiring connector.

5 Check the operation of the headlight.

8.3a Disconnect the headlight wiring connector...

8.3b ... and the sidelight wiring connector

Sidelight

6 Pull the bulbholder out of its socket in the base of the headlight, then carefully pull the bulb out of the holder (see illustrations).

7 Install the new bulb in the bulbholder, then install the bulbholder by pressing it in. Make sure the rubber cover is correctly seated.

8 Check the operation of the sidelight.

8 Headlight assembly -

removal and installation ^

J and K models

Removal

1 Remove the fairing (see Chapter 8).

2 Remove the instrument cluster (see Section 15).

3 The headlights are mounted individually. Disconnect the headlight and sidelight wiring connectors (see illustrations). Release the wiring from any clips or ties on the headlight.

4 Each headlight is secured by three bolts -one at the top and two at the bottom. Unscrew the bolts and remove the headlight, noting how it fits (see illustrations).

5 To separate the beam unit from its holder, first mark each unit according to its side and note the positions of the beam adjusting screws. Check the current aim setting by

7.6a Remove the bulbholder

8.8b ... and the sidelight wiring connector

8.9 Unscrew the three bolts (arrowed) and remove the assembly

9.2 Release the bulbholder ...

8.4a Unscrew the bolts (arrowed)...

8.5 Remove the pivot screw (arrowed)

8.8a Disconnect the headlight wiring connector...

8.5 Remove the pivot screw (arrowed)

8.4a Unscrew the bolts (arrowed)...

measuring the amount of thread projecting from the holder on each beam adjusting screw. Remove the beam unit pivot screw and open the pivot cover (see illustration). Also remove the two headlight beam adjusting screws. Lift the beam unit off the holder, noting how the pivot locates, and remove the adjuster springs. Remove the captive nuts from the beam unit.

Installation

6 Installation is the reverse of removal. Make sure all the wiring is correctly connected and secured. Check the operation of the headlights and sidelights. Check the headlight aim (see Chapter 1).

L, N and R models

Removal

Note: R models are not equipped with sidelight bulbs.

7 Remove the fairing (see Chapter 8).

8 To remove an individual headlight, disconnect the headlight and sidelight wiring connectors (see illustrations). Release the wiring from any clips or ties on the headlight. Carefully pull the top inner corner of the headlight away from the mounting bracket to release the pivot ball from its socket (see illustration). Now slide the headlight sideways out of the bracket, pushing in on the adjuster springs to help release them from their slots in the bracket if necessary.

9 To remove the complete headlight assembly, disconnect the headlight and sidelight wiring connectors for both headlights (see illustrations 8.8a and b). Release the

9.2 Release the bulbholder ...

8.8c Pull the unit off the pivot (A) and slide it out to release the adjuster (B) from the bracket wiring from any clips or ties on the headlight. Unscrew the three bolts securing the headlight bracket and remove the headlight assembly, noting how it fits (see illustration).

8.8b ... and the sidelight wiring connector

8.9 Unscrew the three bolts (arrowed) and remove the assembly

Installation

10 Installation is the reverse of removal. Make sure all the wiring is correctly connected and secured. Check the operation of the headlights and sidelights. Check the headlight aim (see Chapter 1).

9 Brake/tail light bulbs -

renewal

1 Remove (J and K models) or raise (L, N and R models) the passenger seat (see Chapter 8).

2 Turn the bulbholder anti-clockwise and withdraw it from the tail light (see illustration).

3 Push the bulb into the holder and twist it anti-clockwise to remove it (see illustration).

8.4b ... and remove the headlight

10.2b Tail light wiring connector (arrowed) - L, N and R models

10.3 Unscrew the nuts (arrowed) and remove the tail light

10.2a Tail light wiring connector (arrowed) -J and K models

10.2b Tail light wiring connector (arrowed) - L, N and R models

10.3 Unscrew the nuts (arrowed) and remove the tail light

10.2a Tail light wiring connector (arrowed) -J and K models

Check the socket terminals for corrosion and clean them if necessary. Line up the pins of the new bulb with the slots in the socket, then push the bulb in and turn it clockwise until it locks into place. Note: The pins on the bulb are offset so it can only be installed one way. It is a good idea to use a paper towel or dry cloth when handling the new bulb to prevent injury if the bulb should break and to increase bulb life.

4 Install the bulbholder into the tail light and turn it clockwise to secure it.

5 Install the seat (see Chapter 8).

10 Tail light assembly -

removal and installation

Removal

1 Remove the seat cowling (see Chapter 8).

2 Either draw back the rubber boot (in front of the tail light on J and K models, and on the right-hand side of the sub-frame on L, N and R models), and disconnect the tail light assembly wiring connector (see illustrations), or turn the bulbholders anti-clockwise and withdraw them (see illustration 9.2).

3 Unscrew the two nuts securing the tail light assembly and carefully remove it (see illustration). If required, turn the bulbholders anti-clockwise and withdraw them from the tail light.

Installation

4 Installation is the reverse of removal. Check

11.3a Turn signal relay (arrowed) -J and K models the operation of the tail light and the brake light.

1 The battery provides power for operation of the turn signal lights, so if they do not operate, always check the battery voltage first. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 30 and 31 for charging system tests. Also, check the tail/signal fuse (see Section 5) and the switch (see Section 20).

2 Most turn signal problems are the result of a burned out bulb or corroded socket. This is especially true when the turn signals function properly in one direction, but fail to flash in the other direction. Check the bulbs and the sockets (see Section 12).

3 If the bulbs and sockets are good, remove the seat cowling (see Chapter 8) for access to the relay, which is mounted on the right-hand side on J and K models and the left-hand side on L, N and R models (see illustrations). Disconnect the wiring connector and check for power at the turn signal relay black/brown wire (J, K, L, N models) or brown/wire wire (R model) with the ignition ON (see illustration). Turn the ignition OFF when the check is complete.

4 If no power was present at the relay, check the wiring from the relay to the ignition (main) switch for continuity.

5 If power was present at the relay, using the appropriate wiring diagram at the end of this Chapter, check the wiring between the relay, turn signal switch and turn signal lights for continuity. If the wiring and switch are sound, renew the relay.

12 Turn signal bulbs - renewal ^

J and K models Front

1 Remove either the air duct or the fairing side panel for the best access to the turn signal (see Chapter 8).

2 Turn the bulbholder anti-clockwise and withdraw it from the lens (see illustration 13.2).

3 Push the bulb into the holder and twist it anti-clockwise to remove it. Check the socket terminals for corrosion and clean them if necessary. Line up the pins of the new bulb with the slots in the socket, then push the bulb in and turn it clockwise until it locks into place.

4 Fit the bulbholder back into the lens and turn it clockwise, making sure it is securely held.

Rear

5 Remove the screw securing the turn signal lens and remove the lens, noting how it fits

11 Turn signal circuit - check

11.3b Turn signal relay (arrowed) - 11.3c Disconnect the wiring connector

L, N and R models and test as described

12.5 Remove the screw (arrowed) and detach the lens

(see illustration). Remove the rubber gasket if it is free, and discard it if it is damaged or deteriorated.

6 Push the bulb into the holder and twist it anti-clockwise to remove it. Check the socket terminals for corrosion and clean them if necessary. Line up the pins of the new bulb with the slots In the socket, then push the bulb In and turn it clockwise until it locks into place.

7 Fit the lens onto the holder. Use a new rubber gasket if required, and make sure it is properly seated and not pinched by the lens.

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