5.1d ... or remove the cover securing screw circuits. The fuse block on most models also contains accessory output terminals (positive and negative).

Caution: Before connecting an accessory to the output terminals, check with a dealer service department to make sure the accessory is compatible with the motorcycle's electrical system.

2 If you have a test light, the fuses can be checked without removing them. Turn the ignition to the On position, connect one end of the test light to a good ground (earth), then probe each terminal on top of the fuse. If the fuse is good, there will be voltage available at both terminals. If the fuse is blown, there will only be voltage present at one of the terminals.

3 The fuses can be removed and checked visually. If you can't pull the fuse out with your fingertips, use a pair of needle-nose pliers. A blown fuse is easily identified by a break in the element (see illustration).

4 If a fuse blows, be sure to check the wiring harnesses very carefully for evidence of a short circuit. Look for bare wires and chafed, melted or burned insulation. If a fuse is replaced before the cause is located, the new fuse will blow immediately.

5 Never, under any circumstances, use a higher rated fuse or bridge the fuse block terminals, as damage to the electrical system - including melted wires, ruined components, and fire - could result.

6 Occasionally a fuse will blow or cause an

5.3 A blown fuse can be identified by a broken element - be sure to replace a blown fuse with one of the same amperage rating open circuit for no obvious reason. Corrosion of the fuse ends and fuse block terminals may occur and cause poor fuse contact. If this happens, remove the corrosion with a wire brush or emery paper, then spray the fuse end and terminals with electrical contact cleaner.

Circuit breaker

7 A circuit breaker (where fitted) is mounted behind the right frame cover or under the seat (see illustrations). If an overload occurs in the main circuit, the red button on the circuit breaker will pop out approximately 1 to 2 mm (0.040 to 0.080 inch).

8 If the button pops out, let the circuit breaker cool for about ten minutes, then push the button back in.

9 If the circuit breaker continues to pop out, check the wiring harnesses for a short. Never, under any circumstances, bypass the circuit breaker or replace it with a breaker of higher capacity - the overload could damage electrical components, melt wires or start a fire.

6 Lighting system - check s

1 The battery provides power for operation of the headlight, taillight, brake light, license plate light and instrument cluster lights. If

5.7a A circuit breaker is mounted 5.7b ... or behind the right frame cover under the seat (this is a Katana (this is a late GSX-R1100)


none of the lights operate, always check battery voltage before proceeding. Low battery voltage indicates either a faulty battery, low battery electrolyte level or a defective charging system. Refer to Chapter 1 for battery checks and Section 26 for charging I system tests. Also, check the condition of the fuses (and circuit breaker, if equipped), j Replace any blown fuses with new ones or reset the circuit breaker if its red button has popped out.


2 If the headlight is out when the engine is running (US and Canadian models) or won't come on (UK models), check the fuse first with the key On (see Section 5), then unplug the electrical connector for the headlight and use jumper wires to connect the bulb directly to the battery terminals. If the light comes on, the problem lies in the wiring or one of the switches in the circuit. Refer to Section 17 for the switch testing procedures, and also the wiring diagrams at the end of this Chapter.

Taillight/license plate light

3 If the taillight fails to work, check the bulbs and the bulb terminals first, then check for battery voltage at the taillight electrical connector. If voltage is present, check the ground circuit for an open or poor connection.

4 If no voltage is indicated, check the wiring between the taillight and the main (key) switch, then check the switch.

Brake light

5 See Section 11 for the brake light circuit checking procedure.

Neutral indicator light

6 If the neutral light fails to operate when the transmission is in Neutral, check the fuses and the bulb (see Section 14 for bulb removal procedures). If the bulb and fuses are in good condition, check for battery voltage at the neutral switch electrical connector. If batter)' voltage is present, refer to Section 19 for the neutral switch check and replacement procedures.

7 If no voltage is indicated, refer to the wiring diagrams at the end of the book and check the wiring and the bulb for open circuits and poor connections.

Oil pressure warning light

8 See Section 15 for the oil pressure warning light circuit check.

7 Headlight bulb - replacement fe

1 Reach behind the headlight assembly and disconnect the electrical connector (see illustration).

2 Pull up the tab and remove the dust cover (see illustration).

9.2a On some turn signals, the lens is incorporated into the cover (this is a Katana 1100/GSX1100F) - remove the screw and take the lens/cover off...

8.3 Turn the horizontal adjuster to move the beam from side to side

9.2c On other models, the lens securing screws are on the back side of the housing (this is a late GSX-R1100) - remove the screws and lift off the lens

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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