Electrical Troubleshooting Manual - Part 1
Contents
1. 5 GRN GRN GRN GRN Onl INA MENO 170 NM C192 ay m casi C330 J e ee ee ee ee ee eee ee cont d Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc All Rights Reserved MSV 8022 9803 2 9 Ground Distribution G100 G102 G103 and G104 Circuit Schematic cont d p eee INSTRUMENT 1 RIGHT TURN LCD HIGH PANEL SIGNAL ILLUMINATION UNIT BEAM Pages 7 2 INDICATOR TACHOMETER LIGHTS 4 ILLUMINATION INDICATOR 7 3 7 4 zie E oN 1 CUN UM 7 NMANI o 52 NJ LEFT RIGHT RIGHT l HEADLIGHT LEFT HEAD HEADLIGHT SIGNAL SPEEDOMETER RIGHT FAIRING RIGHT FRONT POSITION HEAD LIGHT POSITION INDICATOR ILLUMINATION MARKER LIGHT TURN SIGNAL LIGHT LIGHT LIGHT Optional POSITION LIGHT Page 8 1 8 1 8 1 7 4 4 Page 9 0 Page 9 8 UN GES 7 uad 1 78 Nuus NL A 4 7 can I can l l GRN 4 S20 C67 C66 em AIR PUMP NOISE ASSEMBLY FILTER 5172 LEFT FRONT TURN LEFT FAIRING SIGNAL POSITION MARKER LIGHT LIGHT Optional Page 9 8 Page 9 0 4 7 5168 2 7 Revised May 1998 1998 1 1500 ETM 1998 American Hond2. T Distribution RN E 168 a page 2 11 GRN amp c100 ETM The sample Power Distribution schematic shows how voltage is supplied from the positive battery terminal to the various circuits in the motorcycle Individual circuit schematics begin with a fuse Power Distribution shows the wiring between the battery and the fuses By combining Power Distribution with any individual schematic you get a complete picture of how voltage is applied to the circuit You can use Power Distribution to speed your troubleshooting If Power Distribution shows that an inoperative circuitand a second circuit share a fuse check the operation of the second circuit If it works you know the fuse is good and voltage is available to the inoperative circuit You can then continue troubleshooting 5 Starting 251 System Pag 3 12 STARTER ge 3 RELAY A eo Pages 32 ALTERNATOR Page 3 12 See Ground Distribution page 2 10 Starting System RED Page 3 9 5 G100 00 IGNITION 7 SWITCH 1 i BACK PA UP ACC USE l saol i AL al LIE Dr B BLU ORN YELIBLK Y WD W C58 LT GRN BLK BLU ORN To AA BOX on page 2 4 FUSE qn LT GRN BLK RELAY LT 23 e ACC l To FUSE RED YEL 5A RELAY BOX 1 2 4 ACCESSORY L TERMINAL
3. Troubleshooting SYMPTOM PDAGNOSS e Battery is overcharged or undercharged Blown main fuse B Open WHT circuit to battery open circuit to regulator rectifier or faulty alternator do test A TEST A Power and Ground Check 1 Check for battery voltage at alternator terminal B If yes go to step 2 If no service WHT circuit for an open Disconnect C44 alternator connector Turn ignition switch ON and check for battery voltage at BLK LT GRN circuit If yes go to step 3 If no service BLK LT GRN circuit for an open Reconnect C44 and start the engine Measure voltage across the battery terminals It should measure between 13 5 and 15 5 volts If yes perform a battery load test See service manual charging section If no service or replace alternator See service manual charging section 3 21 Radiator Fans Circuit Schematic 247 FUSE RELAY Box FUSE 10A BLK BLU LEFT RIGHT NOISE NOISE FILTER FILTER LEFT RIGHT RADIATOR RADIATOR FAN MOTOR FAN MOTOR LEFT RIGHT NOISE NOISE FILTER FILTER RADIATOR FAN TEMPERATURE SWITCH Closes at 98 102 C 208 216 F 3 22 Reverse System Circuit Schematic HOT AT ALL TIMES FROM FUSE 8 TAIL BOX MAI IGN START i CRUISE FUSE k RELAY 15A TL ue um ems dus jio emo cm Cue ce cue WH r BRN BLU Ee l GRN 5115 BRN WHT See Power Distribu
4. BRN WHT BRN WHT BRN BRN WHT r pu r I e E 3 LI 23 LEFT SIDE SPOILER RIGHT SIDE TRUNK BRAKE TAILLIGHT TRUNK MARKER CONTROL MARKER LIGHT MODULE LIGHT Optional SE Models Only Optional Page 9 1 Page 9 15 Page 9 1 e S209 211 6 BRN GRN BRN poe fF LEFT LEFT REAR CBS RIGHT REAR RIGHT BRAKE LIGHT ACCESSORY ACCESSORY BRAKELIGHT e TAILLIGHT Vo ucht TAILLIGHT 9 10 9 14 9 14 9 11 D a TRUNK LIGHT ASSEMBLY Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc All Rights Reserved MSV 8022 9803 ETM From Tail Main Relay on page 2 1 BRN WHT BRN WHT c69 Ground Distribution G100 G102 G103 and G104 Circuit Schematic INSTRUMENT 1 ENGINE PU FUEL 1 WHEEL T LCDUNIT PANEL COOLANT GAUGE SPEED 1 Solid state l TEMPERATURE 7 2 SENSOR Pages 5 2 d TOME wy 7 4 gt and 5 1 l GRN BLK Page 7 2 45 68 GRN BLK GRN
5. Marker Instrument Panel Lights page 9 0 page 7 2 BRN WHT 1 BLK GRN 5123 BRN WHT ay BRN WHT BRN WHT To C10 ONY on page 2 5 1 RADIO CB 1 BANE SWITCH SWITCH ILLUMI ILLUMI BRN WHT NATION NATION 9 4 9 4 5121 BRN WHT BRN WHT unm C57 C58 BRN WHT BRN WHT BRN WHT A SE Models Only r 4r r Wr 718NTON Ir a 11 l LOCK ON ipe H S116 11 I 4 BRN WHT BRN WHT 5 1 l 1 RS ore icc 1 C96 C70 position 11 1 7 4 be ee Bi mm LIGHT 11 1 I p 7 4 ca i Pages 9 3 cruisecontro basa Cad and9 6 1 SWITCH C10 LEFT RIGHT ILLUMINATION CORNERING CORNERING LEFT Page 9 4 LIGHT LIGHT RELAY COMBINATION Ld RELAY Asp Models Only SWITCH RIGHT COMBINATION 1 Asp Modele Page 9 3 SWITCH o 113 on nly 7 SE Models Only page 2 4 Page 9 3 cont d Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc All Rights Reserved MSV 8022 9803 2 1 Power Distribution Circuit Schematic cont d From IGNITION SWITCH on page 2 0 From HORN TURN STOP RELAY FUSE on page 2 1 BLK BLK umm 106 71 FUSE RELAY 1 BLK RVSSTART FUSE 5A EE To TAIL MAIN RELAY on BRN WHT page 2 1 C92 HORN T
6. go to self test G SELF TEST B Continuity Test Note Disconnect C42 from reverse control unit Make measurements between G100 terminal and desired pin on connector C42 Power Relay Control 2 Output WHT Battery voltage with ignition switch ON and reverse lever switch in REVERSE If not replace reverse control unit Fully apply rear brake Voltage should drop below 5 volts If not replace reverse control unit If both measurements are correct do self test F Speed Limiter Fuse 65 amp Input YEL Check for continuity to ground G100 If bad check speed limiter fuse 65 amp If good check YEL or BLK circuit for an open If all measurements are good go to the next diagnostic step C42 TERMINAL SIDE Ground Input GRN Check for continuity to ground G100 If there is no continuity repair GRN circuit for an open If OK go to the next diagnostic step Side Stand Switch Input GRN WHT With side stand in UP continuity should exist to ground G100 If not check GRY WHT circuit for an open If OK go to self test D Neutral Switch Input LT GRN RED With transmission in neutral check for continuity to ground If not check LT GRN RED circuit for an open If OK see if neutral indicator illuminates in bulb test and then stays illuminated If bulb doesn t light during bulb test replace bulb If bulb only l
7. replace side stand switch With C28 still disconnected check continuity between YEL BLK and GRN circuits If no replace side stand switch SELF TEST E Gear Position Switch Test 1 Disconnect C59 With the transmission in NEUTRAL check continuity between LT GRN RED circuit and ground If not replace the gear position switch ETM SELF TEST F Power Relay Control Test With suspected relay disconnected apply 12 volts across coil and measure continuity across contacts Power relay control 1 continuity exists Power relay control 2 continuity does not exist if incorrect replace relay If OK go to next step 2 Power relay control 1 check continuity of BLK circuit from contacts and repair if necessary Power relay control 2 check continuity of WHT circuit from contacts and repair if necessary If all measurements are OK go to self test H SELF TEST G Speed Limiter Relay Test 1 With relay disconnected apply 12 volts across the and measure continuity across contacts continuity should exist If not replace speed limiter relay If OK go to next step 2 Check continuity of WHT circuit and YEL circuit from contacts and repair if necessary If OK go to self test H SELF TEST H Reverse Resistors 1 Disconnect starter reverse motor termina connector from reverse resistors 2 Disconnect connector C316 and measure between all wires and terminal from previous step 3
8. 19 Charging System Circuit Schematic Starting System MAIN FUSE B 55A 5187 RELAY IGN START BOX CRUISE FUSE 15A WHT Fuse See Ground l RELAY Distribution l Ts 2 6 l 2 l IGN G100 CRUISE RELAY Jo a U a m yo a ao a a a o TT See Power Distribution 5251 RED WHT 292 9 2 WHT BLK LT GRN RED WHT WHT GRN With RED WHT CB Radio Engine BANK Control e ex 5180 ANGLE System INLINE y SENSOR CAPACITOR BLK LT GRN B C11 BLK LT GRN 5165 BLK J B GRN Q IG IN LINE Regulator CAPACITOR Field Stator Rotor See Ground oe Distribution x page 2 7 GRN E G100 3 20 ETM How the Circuit Works The alternator generates an alternating current AC voltage in its windings as it is driven by the engine The integral regulator rectifier converts this AC voltage into direct current DC voltage to maintain battery charge and operate the electrical system When the engine is running battery voltage is supplied to the alternator regulator through the BLK LT GRN circuit The alternator then supplies voltage to the battery and electrical system through the WHT circuit Capacitors are connected to each alternator terminal to reduce alternator electrical noise
9. BLK C107 C16 l LII III 4 GRN BLK GRN BLK GRN BLK GRN BLK 7 FUEL l LEVEL SENDER 145 Page 7 2 GRN BLK GRN BLK C66 C112 GRN BLK C55 GRN BLK GRN BLK Ce enn GRN BLK BATTERY 1 SPEED LIMITER FUSE 1 65A Page 3 26 2 6 T RELIEF REAR f CRUISE f TURN SOLENOID SUSPENSION coNTROL SIGNAL I VALVE SOLENOID I 1 UNIT l SWITCH Page 5 3 4 3 Pages 9 6 Page 5 3 amp a and 9 7 C135 GRN GRN Tr RIGHT e CORNERING 5164 Gasa T 7 BANK 1 REVERSE Page 9 3 l ANGLE CONTROL l SENSOR 1 t 24 Mod CRUISE 3 Pages 3 10 LL m 00518 Onl CONTROL GRN and 3 20 42 y SWITCH Git GRN GRN ILLUMINA GRN 165 TION e gt GRN Without CB Radio FUEL FRONT i i em FR With CB Radio PUMP ACCES FUEL Page 3 2 RIGHT SORY pump 1 HORN LIGHT L 4 3 2 oo 2158 5 0 9 14 f ENGINE I CONTROL Asp Jis 4 3 DULE 1 a2 PF EOM eang C27 SE Models com d Page3 0 C178 SE Only C49 GRN SIN 3 IN LINE RIGHT GRN 19 CAPACITOR f NCOR C69 C57 7 NERING GRN ARN LIGHT GRN Page 9 3 C183 A
10. BRN RED BRN RED 302 G100 C10 Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc All Rights Reserved 3 2 4 MSV 8022 9803 ETM p REVERSE Reverse CONTROL FUSE RELAY RRA EN Output Side Do not check RVS START Energizes relay for Engine Stand resistance FUSE 1 second Monitor Switch I 5A then deenergizes Input Input e 14 5 10 1 2 BLU RED BRN WHT C32 BEM BLU RED C92 S250 1 mmm indicators REVERSE c22 SAVARD LEVER YEL RED BLU RED F SWITCH x REVERSE PRESSURE DIODE SWITCH ASSEMBLY Open above C92 AEn 1 3 psi WHT C32 YEL RED we 0 1 0 2 kg cm2 303 mr EE ELE 310 BLK 1 L 1 From S302 WHT IT 6665 x EUM c73 YEL RED on page 3 24 BLK I GRN WHT WHT ese C32 YEL RED BRN RED rr INSTRUMENT C30 PANEL Lumen m ua REVERSE Swine From STARTER RELAY B 3 26 C30 LT GRN RED BLK RED i BLU RED Y C66 02 LT eme Y GRN RED BLK RED BLU RED C55 m GRN VE 9 REVERSE Engine is Ce DIODE Control ASSEM System Ko BLY l l le 4 REVERSE j CONTROL GEN on Switch UNIT Input E GRN ORN Solid state GRN WHT L 4 Do not check Sd pu
11. ENGINE Lg J GRN CONTROL MODULE C186 Asp or Int r ecm C127 SE CIL aj Page 3 0 C178 SE cag CRUISE age 9 5 EPI C183 Asp or Int C178 SE From 157 on following page GRN 167 GRN e GRN From C55 5168 4 on page 2 14 GRN Due idm M MC Pad TERI PES MMC EB G100 PARTIAL Component The Component Location Index Section 11 lists every component connector and ground describes its location on the motorcycle This index also gives references to component location photographs which are found in Section 12 Component Location Photographs Section 12 show the exact location and appearance of components connectors and grounds The Component Index Section 13 lists all components and gives page references to all circuit schematics in which each component appears Component Location Index section 11 Refer to Section 12 for photographs Component Photo No Auxiliary Input Connector 55 Behind left fairing pocket Bank Angle Sensor 32 Component or Below right rear of seat Connector Dumba se on frame rail C6 UEBLK as sees sone vee x cor cidu daremus R 45 di ment Number of Cavities ipie uiia Photo In Connector 0 22 BLU SE x sexs op nas nep eem 38 Nurribar Behind left rear of seat in Section 11 Connector Color C10 22 WHT Asp 38 Below left rear of seat Component Index se
12. Ground l Distribution eS ery rs ee aaa REVERSE page 2 7 FORWARD LEVER SWITCH 4 c100 C57 C92 YEURED BLKWHT WHT BLU Reverse System YEL RED Reverse 5198 System YEL RED Radio Cassette A YEL RED Deck CB Transceiver y To STARTER RELAY A To S303 on page 3 11 on page 3 11 3 10 From REVERSE LEVER SWITCH on page 3 10 BLK WHT BLK WHT e BLK WHT 303 C32 sw Y C66 BLK WHT BLK WHT PETTITT INSTRU MENT NEUTRAL PANEL NP 78 7 REVERSE gt Reverse DIODE 5229 System See Ground 07 ASSEMBLY RED Distribution Sees the Sas 23 l Reverse C312 page 2 6 LI System LT GRN RED RED a vs Y IN LINE G100 FUSEB c66 ca BRN RED 5A LT GRN RED YEL RED m O58 E C30 YEL RED REVERSE SWITCH RELAY STARTER eranN RED a RELAY B C30 BLK RED BLU RED a a NUR et E T RR Reverse LT GRN RED 1 BLK RED System REVERSE DIODE D6 p1 ASSEMBLY l LI m d LT GRN RED GRN RED I Reverse LT GRN RED Y 306 GRN ORN GRN RED Y System LT GRN RED Lu C32 BLK GRN RED my CLUTCH Control SWITCH LT GRN RED System Closed when lever depressed LT GRN RED 5186 6 GBRAWHT 6420 LT GRN RED C181 mm Reverse R SR p gerere System GRN ORN 5257 rmm mme starting System YEL BLK Se ead indicators C59 STARTER C28 REVERSE GRNWHT I YEL BLK LT GRN
13. RED MOTOR SIDE STAND SWITCH ETE YT 2 POSITION SWITCH se REVERSE See Ground c28 SWITCH Distribution i B 4 00 age 2 8 reverse 8 100 Loses e ad From STARTER REVERSE SWITCH on page 3 10 YEL RED Y BLK pes P BRN RED 302 ETM See Power Distribution page 2 0 STARTER BATTERY RELAY A 3 11 Starting System How the Circuit Works The starting system for the Asp and SE models is made up of the following components Bank angle sensor Clutch switch Gear position switch Ignition cruise relay Reverse diode assembly Reverse lever switch Reverse switch Reverse switch relay Side stand switch Starter relay A Starter relay B Starter reverse motor Starter reverse switch The starter reverse switch receives battery voltage from the GN cruise relay when the ignition is switched ON The bank angle sensor supplies ground to the IGN cruise relay The starting system is activated when the driver presses and holds the starter reverse switch Voltage from the iGN cruise relay is then sent through the reverse diode assembly reverse Switch relay coil and gear position switch to ground The reverse switch relay energizes and completes a ground path from the coil of starter relay A to ground through the reverse diode assembly clutch switch and the side stand switch St
14. Troubleshooting cont d TEST A1 Power and Ground Reverse Lever Switch Isolation 1 Disconnect C92 reverse lever switch and with ignition switch ON check for battery voltage at BRN WHT circuit If yes replace reverse lever switch If no service BRN WHT circuit for an open or short to ground TEST 2 Power and Ground isolation 1 Disconnect C57 starter reverse switch and with ignition switch ON check for battery voltage at BLK LT GRN circuit If yes go to test A3 If no go to test A4 TEST A3 Power and Ground Starter Relay A Isolation 1 Reconnect C57 and disconnect C41 starter relay A With ignition switch ON check for voltage at YEL RED circuit with starter reverse switch depressed If yes go to step 2 If no service YEL RED circuit for an open If OK replace starter reverse switch Check for battery voltage at starter relay A BLK circuit from battery If yes go to step 3 If no repair BLK circuit With ignition switch ON gearshift in NEUTRAL and reverse lever switch in the FORWARD position check for voltage between BLK battery feed circuit and C41 BRN RED using a test light If yes go to step 4 if no sevice BRN RED circuit for an open between starter relay A and 5302 Check for battery voltage across BLK circuits at starter relay A If yes go to step 5 If no service BLK circuit between starter relay and 5227 for an open Reconnect C41 and disconnect BLK circuits at starter
15. and WHT BLU circuits between ECM and ignition pulse generators for an open If no replace ignition pulse generator Test D Fuel Pump Control Test Gasoline is flammable and is explosive under certain conditions Do not smoke or allow flames or sparks in your working area Immediately wipe up any spills 1 Disconnect C184 except Asp model or C185 Asp model Momentarily jumper BLU circuit fuel pump side to battery voltage Fuel pump should run If yes service BLK BLU circuit between ECM and C184 or C185 for an open If no go to step 2 2 Disconnect C127 except Asp model or C186 Asp model Check GRN circuit Asp model or GRN BLU circuit SE model for continuity for ground If yes service fuel pump If no service GRN or GRN BLU circuit for an open Test E Ignition Coil Input Test 1 Connect ohmmeter across BLK WHT and YEL BLU circuits at ignition coil side of C54 Resistance should be about 4 ohms If OK service YEL BLU circuit between ECM and C54 for an open If not OK service ignition coil Engine Control System Troubleshooting cont d Test F Ignition Coil Input Test 1 Connect ohmmeter across BLK WHT and YEL RED circuits at ignition coil side of C54 Resistance should be about 4 ohms If OK service YEL RED circuit between ECM and C54 for an open If not OK service ignition coil Test G Ignition Coil Input Test 1 Connect ohmmeter across BLK WHT and YEL WHT circui
16. display when M button on radio is pressed Controlled by the mute switch tea AMB seme ri external noises may be heard selected Displays AM or FM station dependent on AM FM switch Displays if FM station is received in stereo When cassette player is loaded Controlled by headset and radio is turned on this will speaker control knob indicate tape direction of play Indicates that sounds are fast forward or rewind direction present on the headsets and not the speakers The Tape Music Sensor indicator n is displayed when a cassette is Clock is displayed when engaged and the search lever ignition switch is in R ACC has been pushed upward or or ON downward The cassette then advances or rewinds to the next pause in music The corresponding direction indicator blinks to indicate tape direction To check air pressure in system press P Check button and time will be removed from display and air pressure will be shown in psi for American models and kg cm for Canadian models 1 17 Power Distribution Circuit Schematic BLK FUSEB BATTERY 55A MAIN STARTER Page 3 20 26 FUSEA RELAY A 9 ee 30A Page 3 11 ALTERNATOR Page 3 20 1 BRN RED Starting System RED Page3 11 C58 7771 IGNITION LT GRN BLK gt BLK BLU ORN To FUSE RELAY BOX on page 2 4 To FUSE RED YEL RELAY BOX on page 2
17. on the symptoms and your understand ing of the circuit s operation identify one or more possible causes of the problem Isolate The Problem By Testing The Circuit Make circuit tests to check the diagnosis you made in step 2 Keep in mind that a logical sim ple procedure is the key to efficient trouble shooting Testforthe mostlikely cause offailure first Try to make tests at points that are easily accessible Fix The Problem Once the specific problem is identified make the repair Be sure to use proper tools and safe procedures Make Sure The Circuit Works Turn on all components in the repaired circuit in all modes to make sure you ve fixed the entire problem If the problem was a blown fuse be sure to test all of the circuits on that fuse Make sure no new problems turn up and the original problem does not recur 1 10 Test Equipment Volimeter and Test Light CAUTION A number of circuits include solid state devices Voltages in these circuits should be tested only with a 10 megohm or higher im pedance digital multimeter Never use a test light on circuits that contain solid state de vices Damage to the devices may result On circuits without solid state devices use a test light to check for voltage A test light is made up of 12 volt bulb with a pair of leads attached After grounding one lead touch the other lead to vari ous points along the circuit where volt
18. the manual in Section 12 Within a section the pages are numbered using the section number a dash and then a consecutive number beginning with zero So if there are three pages in Section 2 the pages will be numbered 2 0 2 1 and 2 2 Outline of Each Circuit Section A Circuit Schematic wiring diagram starts off each section Schematics show e how all the components within a circuit work together current flow from the power source top of page to ground bottom of page switch positions shown at rest as if the ignition was off special instructions Solid state Do not check resistance those circuits sharing a common power source or ground A System Description How the Circuit Works appears in some sections it explains basic circuit operation A Troubleshooting guide also appears in some sections and provides step by step instructions for diagnosis and repair it includes symptom and diagnosis charts and self tests for all possible measurements in the system Model Abbreviations for 1998 used in this manual Asp Aspencade SE Special Edition Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc Rights Reserved 1 1 MSV 8022 9803 T How To Use This Manual Symbols The abbreviations and symbols explained here are used throughout the manual You ll need to know what they mean before you can use the schematics effectively Wire Color Abbreviations Thefollow
19. the cause of the short circuit cas METER cas L SWITCH PULSING FIELD EM f c ca 1 1 1 1 I 1 1 1 T 1 1 1 2 x NEEDLE STOPS MOVING HERE W SHORTTO GROUND NO 2 PULSING MAGNETIC SOLENOID 1 14 Troubleshooting Precautions Before Troubleshooting Check the main fuse and the fuse relay box Checkthe battery for damage state of charge and clean and tight connections CAUTION e Do not quick charge a battery unless the battery ground cable has been discon nected or you will damage the alternator diodes Do not attempt to crank the engine with the ground cable disconnected or you will se verely damage the wiring While You re Working Make sure connectors are clean and have no loose pins or receptacles Make sure multiple pin connectors are packed with silicone grease Pack with silicone grease lt gt 4 RR e Donotpullonthe wires when disconnecting a connector Pull only on the connector housings CAUTION Whenconnecting a connector push It until it clicks into place Refer to page 1 10 for cautions about trou bleshooting circuits that contain solid state devices ETM 1 15 Fuse Information Fuse Relay Box TERMINAL STOP LIGHTS RELAY HEADLIGHTS HIGH RELAY POSITION R
20. the load side 3 Connectthe other lead to a known good ground 4 Beginning near the fuse relay box wiggle the harness Continue this at convenient points about six inches apart while watching the test light or ohmmeter 5 Iftheself poweredtestlight blinks or the ohmme ter needle moves there is ashortto ground in the wiring near that point BATTERY DISCONNECTED FUSE RELAY BOX FUSE REMOVED le SHORTTO GROUND SELF POWERED TEST LIGHT or OHMMETER LOAD DISCONNECTED SOLENOID 1 13 How To Use This Manual Troubleshooting Tests cont d Testing for a Short with a Short Circuit Locator 1 Remove the blown fuse Leave the battery con nected 2 Connectthe shortfinder across the fuse terminals 8 Close all switches in series in the circuit you re testing SHORT FINDER RELAY BOX 4 Turn on the short circuit locator It sends pulses of current to the short This creates a pulsing mag netic field around the wiring between the fuse cis relay box and the short cis ca 5 Beginning at the fuse relay box slowly move the short finder along the circuit wiring The meter will show current pulses through sheet metal and plastic As long as the meter is between the fuse and the short the needle will move with each cur rent pulse Once you move the meter past the point of the short the needle will stop moving NET Check around this area to locate
21. to test C o ex AJo Fuel Pump Control Output BLK BLU Momentarily jumping to battery voltage operates fuel pump If not go to test D Ignition Input BLK WHT Battery voltage with ignition switch ON and stop engine switch in RUN If not check BLK WHT circuit for an open If circuit is OK service right combination Switch ISOLATION PROCEDURE 2 Note Perform all checks in order If a result is incorrect go to the test referenced If a result is correct perform the next check If a box is not numbered do not check 6 Side Stand Input GRN WHT Continuity to ground with side stand UP and open with side stand DOWN If not check GRN WHT and GRN circuits for an open or short to ground If circuit is OK service side stand switch 13 Neutral Input LT GRN RED Battery voltage with ignition switch ON 2a 11 24 11 reverse lever in FORWARD and transmission not in NEUTRAL If not service neutral indicator circuit for an open or short to ground Zero volts in NEUTRAL If not check LT GRN RED circuit and gear position switch for an open 2ND Gear Input BLK YEL Continuity to ground with transmission in 2nd gear otherwise open If not check BLK YEL circuit for an open or short to ground between ECM and gear position switch If circuit is OK service gear position switch 3RD Gear Input WHT RED Continuity to ground with transmission in 3rd gear otherw
22. 1998 GL1500 A SE ELECTRICAL TROUBLESHOOTING MANUAL Contents How To Use This Manual Troubleshooting Hints Fuse Information LCD Unit Display Circuit Schematics see Circuit Index Component Location Index Component Location Photographs Component Index Circuit Index Accessory Lights Automatic Level Control Brake Lights CB Radio Asp CB Radio SE Charging System Clock Cornering Lights Cruise Control Engine Control System Gauges Ground Distribution Handlebar Switch Illumination Hazard Lights Headlights Horn Illumination Lights Indicators Instrument Panel License Plate Light Low Fuel Warning Marker Lights Fairing and Trunk Saddlebags Oil Pressure Warning Parking Lights Position Lights Power Distribution Radiator Fans Radio Radio and Cassette Reverse System Speed Sensor Circuit Spoiler Brake Taillight SE Model only Starting System Taillights Trunk Light Turn Signal Lights 9 14 5 2 9 12 10 14 10 16 3 20 5 1 9 3 4 0 3 0 7 2 2 6 9 4 9 6 8 0 5 0 7 3 7 0 7 2 9 10 60 9 0 9 2 6 0 9 10 9 6 2 0 3 22 10 0 3 24 7 4 9 15 3 10 9 10 9 13 9 6 Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co inc All Rights Reserved MSV 8022 9803 How To Use This Manual Page Numbering System This manual divides the electrical system into individual sections For example Section 5 includes all Chassis Accessories Component Location photographs are atthe back of
23. 22 9803 ETM 1 TRUNK ly ACCESSORY RIGHT N RIGHT ASSEMBLY BRAKE LIGHT REAR TURN Pagos 9 9 Paesi TAILLIGHT SIGNALLIGHT Joi _ d GRN GRN 5157 GRN C76 GRN pP e m g l LeFTREAR LICENSE RIGHT SIDE TRUNK RIGHT SAPDLERAG PLATE MAR LIGHT TRUNK LIGHT ASSEMBLY ari une 911 2 _ pageot1 Pages pre me BRAKE T 7N 7 LEFTREAR LEFT m lq puen 4 N gt N ON cw TURN BRAKE E 1 DL Ned Nev SIGNAL LIGHT LIGHT can LIGHT TAILLIGHT 3 can B 97 5271 4 GRN 5270 GAN GRN GRN 5160 75 GRN C75 SPOILER BRAKE HAZARD C77 5159 CONTROL LEFT SIDE TRUNK N FLASHER LEFT SADDLEBAG MARKER LIGHT STARTER RELAY MODULE RELAY LIGHT ASSEMBLY Optional REGULATOR SE Models adi page Page 9 1 Page 3 24 Page 9 15 dia CON 7TN ON 1 1 E uicur 7 NC NA M TAILLIGHT ew py l GRN GRN GRN a Goa ud 5267 C329 4 Lt GRN C85 can C84 GRN 5206 GRN YEL C330 S161 C86 e GAN C35 YEL m C331 ro LEFT 7 LEFT GRN PN 1 CORNERING J CORNERING LIGHT SPOILER ie DR Ln MET t 1 RELAY Page 9 3 5149 BRAKE SZ Page9 3 ss 150 TAILLIGHT c96 sal C95 C10
24. 4 LT GRN BLK To FUSE RELAY BOX LT eme on page 2 2 c88 LT GRN BLK oY HAZARD FLASHER RELAY LL Page 9 7 GRN LT GRN C103 RED YEL LT GRN BLK BLK BLK LT GRN S101 e LT GRN AIR PRESSURE 103 278 CONTROL RED YEL LT GRN BLK LT GRN BLK ao SWITCH T C66 ASSEMBLY RED 52 YEL C71 E IER LT GRN BLK Page C89 102 NC 104 I RED YEL LT GRN GRN RED YEL ore 108 7 C107 LT GRN LT GRN LT GRN RED YEL BLK _ C4 SE 18 BLK EN TRUNK merta CB 5 10707743 77 7 LIGHT aS CEIVER 9 13 L JPages5 1 4 DECK 10 16 10 0 2 0 ETM FUSE RELAY BOX r l l HORN TURN TAIL METER AIR STOP l STOP RELAY POSITION PUMP FUSE FUSE FUSE FUSE 15A 1 15 15A WHT GRN M 10A l wr From 106 Meli 1 2 2 r WHT BLU i Contact 1 AIR RELAY HORN TURN LI RELAY on Page 5 2 2 2 pee TAIL peres Contact HEAD MAIN Contact stop LIGHTS LIGHTS LL La HIGH Paga 9 10 r V RELAY HELAY 1 Page 9 12 8 1 See Ground l Distribution 2 8 l Se ee ee BRN WHT Am To splice on page 2 5 See Indicators See Headlights page 7 0 page 8 0
25. BLU wires are both in connector C134 RED BLU COMI C134 BLU RED RED BLU Splices 5 Splices S are numbered and Shown as a dot The location and connection of these splices may vary depending BLK BLK EE Q 5218 on the harness manufacturer BLK Connectors Female Each connector C is Connector numbered for reference in the Component Location Index Section 11 Male Connector The index also lists the total number of cavities and the color of the connector Wires may not be used in all cavities Empty Cavity This means the connector connects directly to the GRY component aH This indicates the connector connects to a lead pigtail wired directly to the component This indicates a screw terminal on the component ee Q ETM Components A solid border line means the entire component is shown A broken border line indicates 1 that only part of the component i i l is shown component BRAKE appears next to its upper SWITCH right corner Closed with pedal depressed 2 Notes about component function follow its name Ground G This symbol means the end of the wire is attached to a metal part of the motorcycle Each wire ground G is numbered for reference in the Component Location Index Section 11 G101 This ground symbol dot and 3 lines overlapping the component me
26. ELAY AIR PUMP RELAY HEADLIGHT IGN CRUISE RELAY F Identification Circuit or Component Protected Acc Optional accessories Terminal Horn Turn Horns Horn turn relay coil Position relay coil Stop light relay coil Stop Relay Turn signal cancel control unit Turn signal flasher relay coil Stop Brake lights Fan Cooling fans Head Headlights Instrument panel indicators Air Pump Auto level control system Parking Air pump outlet Parking lights Tait Accessory lights Instrument panel gauges Instrument panet indicators Meter Cornering lights Headlight relays License plate light Position lights Position Side marker lights Taillights Reverse system control Handlebar illumination RVS Start 5 Reverse system Air pump relay CB radio Stereo cassette deck Hazard lights Instrument panel indicator illumination Wheel speed sensor Ign Start Bank angle sensor Charging system Cruise control indicators Cruise Emission controls Engine control module ECM Ignition coils Ignition cruise relay coil Starting system Head Relay 5 Headlights high amp low relay coils Back Up 5 CB radio Stereo cassette deck Instrument panel indicator illumination Trunk light 1 16 LCD Unit Display ETM When Radio is in the scan mode this indicator blinks Controlled by the AMB button This ambience circuit blends frequencies from both channels for a live performance effect Blinks on
27. GRN PULSE SECONDARY AIR INJECTION PAIR SOLENOID VALVE BLK RED C315 C49 MTM A Tm TcOTDUTTDTMUOTUSATOTO ENGINE i RRN CONTROL Switched Ground MODULE Over Side ECM Neutral 2nd 3rd 4th Drive Stand Solid state 1 Input Input Input Input Input Input Do not check 22 21 20 19 5 23 4 resistance EE C49 See Starting System Starting System GRNWHT M GANWHT Reverse System Reverse System GRNIORN d Indicators 257 6 ra ra pages 3 11 and 3 25 LT GRN BLK WHT RED GRN RED YEL RED WHT o 5 GRN OBN GRN WHT 1 28 GRN Cruise E ah 5186 ORN RED WHT Contro SPNet 5144 r r SIDE STAND LT GRN RED RED 1 SWITCH POSITION SWITCH See Ground Distribution Engine Control System Circuit Schematic cont d CONTROL Coolant Ambient Speed Input Fuel Pump MODULE Temp Input Temp Input Common _ Control Output ees Lihat LL L ili Solid state T eR Do not check resistance GRY GRN BLK WHT YEL WHT BLU FRR _____ C60 IGNITION IGNITION PULSE WHT BLU PULSE PNK WHT wHT YEL GENERATOR GENERATOR C314 1 2 ENGINE INTAKE AIR OR WITH ENGINE COOLANT TEMPER RUNNING TEMPER ATU
28. Ifresistance is above 2 ohms for any measurement replace reverse resistors 3 33
29. RE ATURE SENSOR ECT CRANKSHAFT SENSOR YEL BLU GRN BLK GRN BLK YEL GRN BLK C60 GRN BLK BLU bs As p 5198 Asp With Without SE CB Radio CB Radio f 178 184 BLK BLU BLK BLU BLK BLU 1 IN LINE 1 IN LINE l CAPACITOR D J C184 LT BLU BLK BLU C178 ow C185 BLU C184 Blu BLU FUEL FUEL FUEL PUMP PUMP PUMP Wc f 186 127 C178 en GRN BLU 3 71 IN LINE r 1 IN LINE I caPACITOR D capacitor D J GRN GRN C178 C183 GRN GRN C191 C191 cii 4 C191 See Ground Distribution ti page 2 7 8 100 3 2 How the Circuit Works Engine performance is controlled by the engine control module ECM The ECM receives battery voltage when the engine stop switch is in RUN The ECM monitors coolant temperature intake air temperature gear position and engine speed It also controls engine operation by operating several solenoid valves ignition coils and the fuel pump Carburetor Air Jet CAJ Solenoid Valves The CAJ solenoid valves receive battery voltage from the ignition cruise relay with the ignition ON They receive a ground control signal from the ECM Pulse Secondary Air Injection PAIR Solenoid Valve The PAIR solenoid valve receives battery voltage from the ignition cruise relay with the ignition ON It is controlled by a ground control signal from the ECM Ignition Coils The three ignition
30. REVERSE position battery voltage is applied to pin 3 WHT BLU and ground is provided on pin 1 GRN from G100 System Check lf power and ground are OK the reverse control unit then starts a system check to look for the following Battery voltage applied to pin 5 BLU RED when the engine is started and oil pressure is above 1 3 psi Ground presentat pin 8 LT GRN RED whenthe gearshift sensor is in NEUTRAL Ground present at pin 10 GRN WHT when the side stand switch is in the UP position Ground present on pin 12 YEL providing a ground forthe reverse indicator and to establish that the speed limiter fuse is good Whenthe reverse indicator has been illuminated the driver knows the system is ready for operation The driver presses the starter reverse switch and battery voltage is applied to pin 11 YEL RED ofthe reverse control unit As this input is received a set of outputs starts controlling other system components e The reverse control unit provides 9 volts for one second on pin 14 YEL RED to briefly energize the reverse relay switch The reverse relay switch contacts close to provide a one second path to ground This pulls the contacts of starter relay A closed At the same time that pin 14 outputs to the reverse relay switch the reverse control unit grounds pin 7 LT BLU which grounds the starter relay regulator This provides the hold in current path BRN RED to keep the contacts of starter relay A cl
31. RN circuit 3 17 Starting System Troubleshooting cont d TEST E4 Power and Ground Bank Angle Sensor Isolation 1 Reconnect the IGN relay Disconnect C11 bank angle sensor With the ignition switch ON check for battery voltage at RED WHT circuit If yes go to step 2 If no service RED WHT circuit for an open 2 Check battery voltage at WHT circuit If yes go to step 3 If no service WHT circuit for an open 3 Check for battery voltage between WHT and GRN circuits If yes replace bank angie sensor If no service GRN circuit for an open TEST F1 Clutch Switch Isolation 1 Disconnect C325 clutch switch connector With side stand switch UP check continuity of GRN WHT circuit to ground If yes go to step 2 If no check GRN WHT circuit side stand switch and GRN circuit at C28 for an open 2 Disconnect C326 clutch switch connector Check continuity across clutch switch with clutch lever depressed If yes check GRN RED circuit in line diode C and BRN RED circuit for an open If no replace clutch switch TEST G1 Gear Position Switch Isolation 1 Disconnect C59 gear position switch and jumper LT GRN RED circuit to ground With side stand Switch DOWN and ignition switch ON press starter reverse switch Starter should crank If yes replace gear position switch if no check LT GRN RED circuit in line diode A and BRN RED circuit for an open 3 18 3
32. Schematic cont d From IGNITION SWITCH on page 2 0 PARKING FUSE 10A C LT GRN YEL LT GRN YEL T LT GRN YEL GRN C10 YEL C103 LT GRN YEL GRN IN LINE r 7 AIR DIODE B Page 9 11 Outlet PRESSURE g Switch CONTROL L 2 SWITCH 4 ASSEMBLY 5 3 5111 BHN C77 BRN C78 BRN BRN RIGHT BRAKE LIGHT SADDLEBAG TAILLIGHT LIGHT I uuu ASSEMBLY Page s From IGNITION SWITCH on page 2 1 9 5112 BRN C56 BRN M BRN 5113 77 LICENSE gt PLATE ERN LIGHT cai Page 9 11 BRN C85 S273 BRN BRN o S272 BRN BRN C188 Optional r TT CENTER 1 LIGHT ASSEMBLY ASSE BRAKE LIGHT SADDLEBAG eer TAILLIGHT LIGHT EU oe j ASSEMBLY 9 10 BLU ORN BLK BLU From IGNITION SWITCH on page 2 0 TTT TT FUSE RELAY FAN Box FUSE 10A 4 C109 BLU RIGHT LEFT NOISE NOISE FILTER FILTER Page 3 22 Page 3 22 BLU 1 RIGHT r LEFT RADIATOR RADIATOR 1 FAN FAN MOTOR MOTOR Page 3 22 Page 3 22 From S115 on page 2 1 BRN WHT BRN WHT C95 BRN WHT I BRN WHT y fen 78 7 BRN WHT LEFT FRONT RIGHT FRONT ACCESSORY ACCESSORY LIGHT LIGHT SE Models Only SE Models Only Page 9 14 Page 9 14 BRN WHT 210 Ce TT 208 BRN WHT BRN WHT BRN WHT BRN WHT C86 C82 C75 C76
33. URN RELAY l Io See Ground Distribution Pee e WHT GRN BRN WHT page 2 8 471 REVERSE EXT ul ilg LEVER GRN SWITCH C192 109 6 LL L4 Page 3 25 WHT GRN WHT GRN LJ Position C192 fel Ingav I Page 9 7 b GRN 4 L WHT GRN C10 5107 See Ground WES Distribution WHT GRN C87 2 8 EI GRN WHT GRN C81 5108 b ds aid c100 WHT GRN WHT GRN TURN x C57 SIGNAL WHT GRN r 1 FLASHER C320 1 RELAY WHT GRN T7777 FRONT BRAKE Pages 1 Licht swircH Page 9 12 REAR BRAKE LII LIGHT SWITCH Page 9 12 S110 WHT GRN ji C90 WHT GRN WHT GRN C99 WHT GRN CSF LEFT T 4 TURN SIGNAL ty J COMBINATION CANCEL CONTROL SWITCH SWITCH UNIT 5 0 L 4 Page 9 6 tote l l c3 WHT IGN START CRUISE FUSE e WHT RED WHT C33 C32 RED WHT C11 WHT RED WHT prom M a a e e e BLK LT GRN See Engine Control System Starting System Charging System Reverse System Cruise Control BRN RED BRN RED Free Sp ee iii ome ne ee BANK RIGHT ANGLE COMBINATION SENSOR SWITCH 1 Page 3 10 7 71 STARTER REVERSE push SWITCH ETM 7 FUSE RELAY cont d Power Distribution Circuit
34. __ l l LT GRN BLK l A GRN Koi sese m 505 on page 2 2 LT GRN BLK css LT GRN BLK Ir f HAZARD u l Pago FLASHER t RELAY demit L a a Page 9 7 GRN LT GRN RED YEL BLK C103 ein 8103 73 s278 LTGRN AIR PRESSURE RED YEL LT GRN BLK LT GRN BLK SONTROL De L J ASSEMBLY RED BLK oma Page 5 4 YEL C71 RED YEL LT GRN BLK p C89 5102 9 ra cmm 5104 RED YEL RED YEL LT GRN ii 906 A RED YEL E LT GRN BLI LT GRN e Ue LT GRN BLK oma lt TRANS 77 RADIO IIS 7l INSTRUMENT ru PANEL 2 Page9 18 E aum 5 2 LZ LIT DECK ignition and 10 15 10 0 put Lon J Lad LCD UNIT 7 WHEEL SPEED SENSOR cont d How To Use This Manual Circuit Schematic cont d The sample Ground Distribution schematic shows which components share the same ground point r REAR CRUISE l SOLENOID SUSPENSION CONTROL VALVE SOLENOID 1 UNIT l l VALVE Page 4 3 ed Page 5 5 RELIEF 1 GRN rms BANK f 3 REVERSE ANGLE CONTROL SENSOR UNIT I Pagesa Pagest4 and 3 12 b N EI GRN ca2 11 GRI GRN 5165 C33 W O CB RADIO W CB RADIO E Page3 2 Page 3 2 Le a n HORN 71
35. a Meter Co Inc All Rights Reserved 2 10 MSV 8022 9803 2 11 Engine Control System Circuit Schematic PL 4 rst IGN START CRUISE FUSE BOX 15 l l IGN cRUISE RELAY l WHT e Ji BLK LT GRN BLK LT GRN 5180 6 meres Starting System J Bank Angie Sensor BLKILT GAN BLK LT GRN 9 sisi BLK LT GRN C57 BLK LT GRN Hist C55 Star Reverse COMBINATION BLK LT GRN Charging System ENGINE l SWITCH C120 BLk LT GRN BLK LT GRN C119 STOP SWITCH BLK LT GRN 189 BLK LT GRN 4 CARBURETOR CARBURETOR gime a ia AIR JET AIR JET CAJ CAJ SOLENOID SOLENOID BLK WHT Y VALVE 2 VALVE 3 WH RED WHT RED 1 2 15 14 Ignition Switched Ground Speed Switched Ground Control Signal Switched N Switched Switched Switched Output Ground 1 eat SUL A RH E iii BLK WHT E m C49 YEL WHT YEL BLU YEL RED WHT BLK YEL BLU GRN amp C54 C33 YEL WHT YEL BLU YEL RED WHT BLK BLK WHT BLK WHT Instrument Panel BLK WHT 5184 YEL BLU Speed Sensor Tachometer ircuit BLK WHT IGNITION COILS See Ground Distribution page 2 7 um ema G100 SPARK PLUGS ETM BLK LT GRN C315 BLK LT
36. age is not present service circuits for an open Inoperative speed limiter relay do self test A pin 2 No control signal from reverse control unit indicator do self test A pin 4 cont d 3 29 Reverse System Troubleshooting cont d SELF TEST A Static Measurements Note Leave C42 connected to reverse control unit Make all measurements between pin given in domestic table and ground pin 1 Starter Reverse Motor Input PNK Varying voltage present with ignition Switch in ON reverse lever switch in REVERSE and starter reverse switch pushed If not check in line fuse A 5 amp If fuse is good check circuit for an open If all measurements are good do self test A pin 11 C42 HARNESS SIDE Power Relay Control 1 Output ORN Battery voltage with ignition switch ON and reverse lever switch in REVERSE If not replace reverse control unit Lightly apply rear brake Voltage should drop 5 volts If not replace reverse control unit If both measurements are correct go to self test F Starter Reverse Switch Input YEL RED Battery voltage with ignition switch ON and starter reverse switch depressed If not service YEL RED circuit for an open If measurements are correct go to the next diagnostic step Reverse Relay Switch Input Output YEL RED Battery voltage with reverse lever switch in FORWARD If not do self test C 9 volts for approximately 1 second with start
37. age should be present The bulb will go on if there is voltage at the point being tested A voltmeter can be used in place of a test light While a test light shows whether or not voltage is present a voltmeter indicates how much voltage there is Self Powered Test Light and Ohmmeter CAUTION Never use a self powered test light on circuits that contain solid state devices Damage to these devices may result Diodes and solid state devices in a circuit can make an ohmmeter give a false reading To find out if a component is affecting a measurement take one reading reverse the leads and take ase cond reading If the readings differ the compo nent is affecting the measurement An ohmmeter can be used in place of a self pow ered test light The ohmmeter shows how much resistance there is between two points along a cir cuit Low resistance means good continuity Self Powered Test Light Circuits that contain solid state devices should only be tested with a 10 megohm or higher imped ance digital multimeter Use a self powered test light to check for continu ity This tool is made up of a light bulb battery and two leads If the leads are touched together the bulb will go on Aself powered test light is only used on an unpow ered circuit First disconnect the battery or remove the fuse that feeds the circuit you are working on Select two points along the circuit through which there should be continuity Co
38. ans the housing of the component is attached directly to a metal part of the motorcycle cont d How To Use This Manual Symbols cont d Switches These switches move together a dashed line shows a mechanical connection between them e 14 This is a relay shown with no current flowing through its coil Unless otherwise noted all switches are shown in their normal rest position with power off ZN Normally Open Closed Contact Shield This represents RFI Radio Frequency Interference shielding around a wire The shielding is always connected to ground Fuses This means power is supplied when the ignition switch is in ON HOT IN ON 31 rusEe 10A Identification GRN BLK Current rating Diode This diode allows current to flow only in the direction of the arrow How To Use This Manual r Circuit Schematic cont d Circuit schematics break the entire electrical system into individual circuits Electrical components that work together are shown together so that you are not distracted by wiring that is not part of the circuit you are working on Each drawing is arranged so current flows from pos itive at the top of the page to ground at the bottom of the page The HOT label at the top of a fuse shows when the ignition switch supplies power to that fuse Each circuit is shown completely and independent ly on one schematic Other circuits getti
39. arter relay A energizes and applies battery voltage to the coil and contacts of starter relay B when the reverse switch is in the FORWARD position Starter relay B energizes and applies voltage to the starter reverse motor The starter motor turns to crank the engine 3 12 Troubleshooting X paevss e Starter and reverse systems do not operate but the neutral indicator operates Starter and reverse systems do not operate and the neutral indicator does not operate e Starter operates in neutral but not in gear with clutch lever depressed and side stand switch UP Starter operates with clutch lever depressed and side stand switch UP but not with clutch lever released and gear selector in NEUTRAL Neutral indicator does not light but starter Open circuit to instrument panel bulb operates with clutch lever released bulb or reverse diode assembly ETM Weak battery or poor terminal connections Blown RVS Start fuse Open circuit at reverse lever switch or fauity starter reverse motor do test A2 Poor battery terminal connections Blown IGN Start Cruise fuse Open circuit or faulty bank angle sensor IGN cruise relay starter relay A do test A1 Open circuit or faulty reverse diode assembly clutch switch or side stand switch do test C1 Open circuit or faulty reverse diode assembly or gear position switch do test D1 cont d 3 13 Starting System
40. cator lights 3 28 No power to reverse control unit do self test A pin 3 No ground to control module do self test B pin 1 Bad side stand switch input do self test B pin 10 No neutral position input from gearshift sensor do self test B pin 8 Incorrect oil pressure switch input do self test A pin 5 Bad speed limiter fuse 65A do self test B pin 12 Faulty reverse control unit Replace with known good reverse control unit No voltage to starter reverse motor do self test A pin 13 No control signal to reverse control unit from starter reverse switch do self test A pin 11 No control signal from reverse control unit to reverse relay switch do self test A pin 14 No control signal from reverse control unit to starter relay regulator do self test A pin 7 ETM SYMPTOM Reverse system operates but very slowly or no power on inclines Reverse system operates above 2 5 km h down inclines Reverse system operates but reverse indicator doesn t light Faulty control signal from reverse control unit to power relay control 1 do self test pin 6 Faulty control signal from reverse control unit to power relay control 2 do self test A pin 9 Inoperative power relays do self test F If all the above are OK check red circuits to power relay controls for battery voltage with ignition ON starter reverse switch in REVERSE and the starter reverse switch pushed If volt
41. coils receive battery voltage with the ignition ON and the engine stop switch in RUN Each coilis fired individually when the ECM grounds the corresponding coil control line The ECM can vary ignition timing based on other sensor information Gear Position Switch The gear position switch supplies five input circuits to the ECM for the positions N 2 3 4 and OD The respective circuits are ground when in the associated gear and open otherwise Side Stand Switch The side stand switch sends a ground signal to the ECM with the side stand switch in UP and is open in DOWN Troubleshooting Engine cranks but does not start Engine runs poorly ETM Intake Air Temperature IAT Sensor The intake air temperature IAT sensor is a resistor that increases resistance with a decrease in temperature and decreases resistance with an increase in temperature The IAT sensor sends this resistance signal to the ECM through the GRN BLK sensor common and the GRY ambient air temperature input circuit Ignition Pulse Generators The ignition pulse generators are coils that generate a magnetic pulse when the crankshaft magnet passes by the pulse generator pickups This pulsing signal conveys crankshaft position and engine RPM information to the ECM One end of these generators is tied to the GRN BLK sensor common The ignition pulse generator signals are sent to the ECM through the WHT YEL and WHT BLU circuits Fuel Pump The fuel p
42. ction 13 Acc Fuse 10 2 0 5 2 5 4 7 6 9 7 10 0 10 6 10 15 Acc Terminal Fuse 2 0 Accessory 2 0 2 12 Air Pressure Control Switch Assembly 2 0 2 4 5 4 5 5 Air Pressure Sensor 5 4 Air Pump Assembly 2 14 5 5 Air Pump Fuse 10A css sere rnm 2 1 5 4 Ai PUMPIRGIAY uos cqui eet RN SU 2 0 2 1 5 4 How To Use This Manual Five Step Troubleshooting 1 Verify The Complaint Turn on all the components in the problem cir cuit to check the accuracy of the customer complaint Note the symptoms Do not begin disassembly ortesting until you have narrowed down the problem area Analyze The Schematic Look up the schematic for the problem circuit Determine how the circuit is supposed to work by tracing the current paths from the power source through the circuit components to ground Also trace circuits that share wiring with the problem circuit The names of circuits that share the same fuse ground or switch and so on are referred to on each circuit sche matic Try to operate any shared circuits you didn t check in step 1 If the shared circuits work the shared wiring is OK and the cause must be in the wiring used only by the problem circuit If several circuits fail at the same time the fuse or ground is a likely cause Based
43. er reverse switch pushed If not replace control unit If all measurements are correct service YEL RED circuit for an open 3 30 Starter Relay Regulator Output LT BLU Voltage drops from 1 5 volts to 0 volts with the engine running reverse lever switch in REVERSE and the starter reverse switch pushed If not replace the reverse control unit Oil Pressure Switch Input BLU RED 0 volts with ignition switch ON If not check to see if oil pressure indicator operates If so service BLU RED circuit for an open If oil pressure indicator dosen t light replace oil pressure switch Reverse Indicator Output WHT RED With ignition ON see if indicator illuminates for bulb test 0 volts present with the reverse system in operation If not replace the reverse control unit If so short WHT RED circuit to ground and if indicator dosen t illuminate service WHT RED circuit for an open Reverse Lever Switch Input WHT BLU Battery voltage with ignition switch ON and reverse lever switch in REVERSE If not do self test C Speed Limiter Relay Control GRY Battery voltage with ignition switch ON reverse lever switch in REVERSE and starter reverse switch pushed If not replace reverse control unit Push cycle on level ground to exceed 2 5 km h while in reverse operation voltage will drop to below 5 volts If not replace reverse control unit If all measurements are correct
44. ery Connect the negative lead to the other end of the wire or the other side of the connector or Switch Turn on the components in the circuit The voltmeter will show the difference in volt age between the two points A difference or drop of more than one volt indicates a prob lem Checkthe circuitfor loose or dirty connec tions HOT AT ALL TIMES FUSE RELAY BOX RED VOLTMETER E SWITCH HI SOLENOID 1 12 Testing for a Short with a Test Light or Voltmeter 1 Removethe blown fuse and disconnectthe load 2 Connecta test light or voltmeter across the fuse terminals Make sure thatthe voltage is being ap plied to the fuse terminals You might have to put the ignition switch in RUN Check the schematic to see 3 Beginning near the fuse relay box wiggle the harness Continue this at convenient points about six inches apart while watching the test light or voltmeter 4 Whenthetestlight blinks orthe voltmeter needle moves there is a short to ground in the wiring near that point HOT AT ALL TIMES 74 EUSE RELAY NE FUSE REMOVED SHORT TO GROUND TEST LIGHT or VOLTMETER AED SWITCH BLU LOAD 7 DISCONNECTED SOLENOID ETM Testing for a Short with a Self Powered Test Light or Ohmmeter 1 Remove the blown fuse and disconnect the bat tery and load 2 Connect one lead of a self powered test light or ohmmeter to the fuse terminal on
45. ights for bulb test do self test E cont d 3 31 Reverse System Troubleshooting contd 9 3 32 SELF TEST C Reverse Lever Switch Note Consult service manual for mechanical operations and alignment 1 4 With transmission in NEUTRAL and reverse lever switch in FORWARD see if the neutral indicator lights If yes go to step 3 If no go to the next step Check for battery voltage at BRN WHT circuit of reverse lever switch connector C92 If yes go to the next step If no service BRN WHT circuit for an open With C92 disconnected check continuity between e BRN and BLK WHT circuits with reverse lever switch in FORWARD BRN and WHT BLU circuits with reverse lever switch in REVERSE If no continuity exists replace reverse lever switch If all measurements are OK go to the next step Service WHT BLU circuit for an open SELF TEST D Side Stand Switch 1 With the ignition ON and side stand DOWN check to see if side stand indicator lights If yes go to step 3 If no go to the next step With C28 disconnected check for continuity between GRN circuit and ground G100 If yes go to the next step If no service GRN circuit for an open Disconnect C28 and check continuity between GRN WHT and GRN circuits on switch side of connector with side stand switch DOWN If yes go to the next step If no
46. ing abbreviations are used to identify wire colors in the circuit schematics PINK Lut ved dax 3 pink Wires A wavy line means the wire is His broken by the binding of the book but continues on the next page Wire insulation can be one YEL RED color or one color with another color stripe the second color is the stripe rr This means the current path continues on another page The arrow shows direction of current flow To follow the WHT To S285 white wire in this example you would turn to page 9 11 and look for the R arrow This means the branch of the wire connects to another circuit ORN The arrow points to the name of the circuit branch where the wire continues Name of Circuit on page 9 11 A broken line means only some of the circuit is shown refer to the circuit listed for the complete schematic See Ground P aa Distribution page 2 10 G100 Wire choices for options or different models are labeled and shown with a choice bracket like this ORN Without With Rear Speaker Rear Speaker M 9 C309 C310 ORN ORN HOT AT ALL TIMES Where separate wires join 11 FUSE only the splice is shown for details on the additional RELAY wiring refer to the circuits 5 listed L i RED YEL Instrument Panel rcm em siv CB Transceiver RED YEL This dashed line means the BLU RED and RED
47. ise open If not check WHT RED circuit for an open or short to ground between ECM and gear position switch If circuit is OK service gear position switch 4TH Gear Input RED WHT With ignition OFF connect test lamp be tween terminal indicated and battery volt age Lamp lights in 4th gear and is off in all others If not check RED WHT circuit and gear posi tion switch for an open or short to ground Overdrive Input GRN ORN Battery voltage with ignition switch ON If not check GRN ORN and BLK GRN indicator control circuits and bulb for an open or short to ground Zero volts in Overdrive OD If not check GRN ORN circuit and gear position switch for an open cont d Engine Control System Troubleshooting cont d ISOLATION PROCEDURE 2 cont d Ignition Coil Control YEL BLU Resistance to pin 2 BLK WHT is about 4 ohms If not go to test E Ignition Coil Control YEL RED Resistance to pin 2 BLK WHT is about 4 ohms If not go to test Intake Air Temperature IAT Sensor Input GRY Resistance to GRN BLK ECM sensor common is 2k to 3k ohms at 68 F 20 C and 200 to 400 ohms at 176 F 80 C If not go to test L Engine RPM Output Signal Asp and SE models only WHT BLK Continuity to cruise control unit connector C135 Carburetor Air Jet CAJ Solenoid Valve 2 RED WHT Battery voltage with ignition switch ON If not go to test H Carbure
48. ng their power from the same point or grounding at the same point are not shown However if other circuits actually share some wires with the circuit shown the shared wires of the other circuits will also be shown HOT IN ON r See Power Distribution page 2 2 BLK mamme 5105 BLK E See Ground Distribution amma 5109 2 12 C180 179 ou C192 pU X 41 LI ud GRN C192 C191 GRN 5167 GRN ENS GENS EEE See Ground Wires that connect to another circuit are shown with an arrowhead pointing in the direction of current flow The name of the circuit or component that shares the wiring is provided for reference You can check shared wiring by checking the operation of the other circuits See Power Distribution means there are more con nections to other circuits that are not shown Allsuch shared circuits are shown on the Power Distribution circuit schematic See Ground Distribution means there are more shared ground circuits which are shown on the Ground Distribution schematic HOT AT ALL TIMES cuum mas cu emm emm cun FUSE T RELAY HORN TURN BOX STOP RELAY FUSE am am ee 1 WHT GRN See Power Distribution page 2 2 WHT GRN N WHT GRN Turn Signal Cancel 1106 Control Unit 5 LEFT HORN COMBINATION SWITCH RIGHT Distribution um page 2 12 GRN
49. nnect one lead ofthe self powered test light to each point If there is con tinuity the test light s circuit will be completed and the bulb will go on Jumper Wire Use a jumper wire to bypass an open circuit A jumper wire is made up of an in line fuse holder connected to a set of test leads It should have a five ampere fuse Never use a jumper wire across any load This direct battery short will blow the fuse Short Finder Short finders are available to locate shorts to ground The shortfinder creates a pulsing magnet ic field in the shorted circuit and shows you the location of the short through body trim or sheet metal Its use is explained in the following trouble shooting tests ETM Troubleshooting Tests Testing for Voltage This test measures voltage in a circuit When test ing for voltage at a connector you do not have to separate the two halves of the connector Instead probe the connector from the back Always check both sides of the connector because dirt and cor rosion between its contact surfaces can cause electrical problems 1 Connect one lead of test light to a known good ground or if you are using a voltmeter be sure you connect its negative lead to ground Connectthe other lead of the test light or volt meter to the point you want to check Ifthetestlight glows there is voltage present If you are using a voltmeter note the voltage reading It should be within one volt of mea s
50. osed while the starter reverse Switch is pushed Pin 6 ORN is grounded by the reverse contro unit when the starter reverse switch is pushed and minimum load is applied to the motor Pin 9 WHT is grounded when maximum load is applied to the motor System Reset System reset is required when vehicle speed exceeds 2 5 km h or when the starter reverse motor has experienced an electrical motor brake of three seconds or more The reverse control unit monitors the starter reverse motors voltage and if it determines an excessive speed it grounds pin 2 GRY allowing the speed limiter relay s contacts to close This removes some of the voltage to the starter reverse motor If it determines an electrical motor brake then the control unit removes all power to the starter reverse motor by de energizing starter relay A The reverse control unit also provides battery voltage to pin 4 WHT RED turning the reverse indicator off Before the system may be operated again the reverse lever switch must be recycled back to the forward position applying battery voltage to pin 14 YEL RED 3 27 Reverse System Troubleshooting gt gt gt gt gt 55 gt gt gt Reverse system doesn t operate and the reverse indicator doesn t light Reverse system operates for only a few seconds then quits Reverse indicator turns off or reverse system doesn t operate and the reverse indi
51. r Relay A Isolation 1 Reconnect C57 and disconnect C41 starter relay A With ignition switch ON check for voltage at YEL RED circuit with starter switch depressed If yes go to step 2 If no check YEL RED circuit for an open If OK replace starter switch 2 Check for battery voltage at starter relay A BLK circuit from battery If yes go to step 3 If no repair BLK circuit 3 With ignition switch ON and gearshift in NEUTRAL check for voltage between BLK battery feed circuit and C41 BRN RED using a test light If yes go to step 4 If no service BRN RED circuit for an open between starter relay A and 373 4 Reconnect C41 and disconnect BLK circuit at starter motor terminal Connect test light at starter motor terminal With ignition switch ON and gearshift in NEUTRAL press and hold starter switch Test lamp should light If yes replace starter motor If no check BLK circuit for an open If OK replace starter relay A TEST E3 Power and Ground IGN Relay Isolation 1 Disconnect the IGN relay With the ignition switch ON check for battery voltage at both WHT circuits If yes go to step 2 if no service WHT circuit for an open 2 Check battery voltage between WHT and RED WHT circuits If yes go to step 3 If no go to test E4 3 Connect a fused jumper 15A between WHT and BLK LT GRN circuit at IGN relay and check for battery voltage at BLK LT GRN circuit at C57 If yes replace IGN relay If no service BLK LT G
52. relay With ignition switch ON and reverse lever switch in FORWARD check for battery voltage at YEL RED circuit If yes go to step 2 If no go to test B2 Check for battery voltage at BRN RED circuit with starter reverse switch depressed If yes go to step 3 If no service BRN RED circuit for an open Check for battery voltage between YEL RED and BLK RED circuits If yes go to step 4 If no check BLK RED circuit between reverse switch relay and reverse diode assembly for an open If OK replace reverse diode assembly Check for battery voltage between YEL RED and BLU RED circuits If yes go to step 5 If no check BLU RED circuit between reverse switch relay and reverse diode assembly for an open If OK replace reverse diode assembly With ignition switch ON gearshift in NEUTRAL and reverse lever switch in FORWARD connect a fused jumper 15A between BRN RED circuit at C30 and ground The starter should crank If yes replace reverse switch relay If no go to test B4 TEST B2 Reverse Diode Assembly Isolation 1 Disconnect reverse diode assemby connector With ignition switch ON and reverse lever switch in FORWARD check for battery voltage at BLK WHT diode D7 circuit If yes go to step 2 If no go to test B3 Check for continuity at YEL RED circuit between reverse diode assembly and reverse switch relay If yes replace reverse diode assembly If no service YEL RED circuit cont d 3 15 S
53. reverse motor terminal Connect test light at starter reverse motor terminal With ignition switch ON reverse lever switch FORWARD and gearshift in NEUTRAL press and hold starter reverse switch Test lamp should light If yes replace starter reverse motor If no replace starter relay A TEST A4 Power and Ground IGN Cruise Relay Isolation 1 Disconnect the IGN cruise relay With the ignition switch ON check for battery voltage at both WHT circuits If yes go to step 2 If no service WHT circuit for an open Check for battery voltage between WHT and RED WHT circuits If yes go to step 3 If no go to test A5 Connect a fused jumper 15A between WHT and BLK LT GRN circuit at IGN cruise relay and check fo battery voltage at BLK LT GRN circuit at C57 If yes replace IGN cruise relay If no service BLK LT GRN circuit 3 14 TEST A5 Power and Ground Bank Angle Sensor Isolation 1 ETM Reconnect the IGN cruise relay Disconnect C11 bank angle sensor Turn the ignition switch ON and check for battery voltage at RED WHT circuit If yes go to step 2 If no service RED WHT circuit for an open Check for battery voltage at WHT circuit If yes go to step 3 if no service WHT circuit for an open Check for battery voltage between WHT and GRN circuits If yes replace bank angle sensor If no service GRN circuit for an open TEST B1 Reverse Switch Relay Isolation 1 Disconnect C30 reverse switch
54. rum C42 resistance 5257 LT GRN RED LT GRN RED Seen ca2 S306 c28 LT GRN RED GRN WHT GRN ORN C32 PTs 7313 SIDE LT GRN RED y gt l STAND LT GRN RED Engine pur Npows SWITCH 186 6 Control L jr LT GRN RED System om E cos C59 GRN LT GRN RED See GEAR Ground A POSITION Distribution REVERSE N x SWITCH page 2 8 switch P bbs Open in 1 ry reverse l l G100 cont d 3 25 Reverse System Circuit Schematic cont d From S232 From STARTER RELAY A on on page 3 24 page 3 24 WHT BLU C312 WHT BLU WHT BLU IN LINE WHT BLU FUSEB 5A YEL RED From STARTER RELAY A on PE 3 24 REVERSE Fags RESISTORS STARTER RELAY B at a Y C313 Ig GRN RED C32 GRN RED c29 Nurseries c32 Ground iN To REVERSE PNK Output for Reverse Output Output DIODE ASSEMBLY IN LINE Control Indicator Control Control on page 3 25 Signal Circuit 12 Signal Signal 2 C312 ga TEL YEL m 5307 BATTERY C42 REVERSE 727 See Ground CONTROL Monitors Distribution STARTER UNIT Motor 2 6 REVERSE Voltage MOTOR Could c100 3 26 How the Circuit Works The reverse control unit takes a series of inputs from external switches and also monitors voltage developed at the starter reverse motor to determine what outputs should be controlled to make reverse direction possible When the reverse lever switch is in the
55. sp UN SE GRN GRN C178 SE c69 GAN Models _ Only From S157 on page 2 8 GRN c22 GRN C115 GEN From C55 on page 2 10 Revised May 1998 1998 GL1500 ETM 1998 American Honda Motor Co Inc All Rights Reserved MSV 8022 9803 2 7 Ground Distribution G100 G102 G103 and G104 Circuit Schematic cont d pomme Ust HEAD HEADLIGHTS LOW RELAY HORN STOP TAIL LIGHTS RELAY BOX TURN LIGHTS MAIN HIGH Page 8 1 RELAY RELAY RELAY RELAY 2 11 Pail psi TERMINAL I I l l coi l coi E i eels eg eS Sole L ee TURN CB CRUISE SIGNAL TRUNK RADIO SWITCH CONTROL CANCEL LIGHT CASSETTE DRIVER VALVE CONTROL SWITCH DECK Pages 10 15 UNIT UNIT Page 9 13 HORN Page 10 1 and 10 17 Page 4 3 Page 9 6 T 775 Page 5 0 CB RADIO ptm mS mn pan l SWITCH l l 1 ASSEMBLY 1 Eu SE Models Besa bed tu Cad C179 Only 9 4 GRN GRN GRN C131 BLK C99 GRN C89 C23 SE GRN GRN GRN C20 Asp LEFT FRONT ACCESSORY GRN GRN SIDE GRN C90 LIGHT STAND Page 9 14 SWITCH Pages 3 1 f x and 3 11 C179 1 GRN SE Models LE E Only GRN I s147 GAN Two Wire Splice 9 sis7 GRN To 167 on page 2 7 Revised May 1998 1998 GL1500 ETM 2 8 1998 American Honda Motor Co Inc All Rights Reserved MSV 80
56. starter relay B and reverse diode assembly If yes go to step 2 If no service GRN RED circuit for an open With reverse switch in FORWARD check continuity between GRN ORN circuit and ground If yes replace reverse diode assembly If no check reverse switch and GRN ORN circuit TEST C1 Clutch Switch Isolation 1 Disconnect C326 clutch switch connector With side stand switch UP check continuity of GRN WHT circuit to ground If yes go to step 2 If no check GRN WHT circuit side stand switch and GRN circuit at C28 for an open Disconnect C325 clutch switch connector Check continuity across clutch switch with clutch lever depressed If yes check GRN RED circuit for an open If OK replace reverse diode assembly If no replace clutch switch ETM TEST D1 Gear Position Switch Isolation 1 Disconnect C59 gear position switch and jumper LT GRN RED circuit to ground With side stand switch DOWN reverse switch in FORWARD and ignition switch ON press starter reverse switch Starter should crank If yes replace gear position switch If no check LT GRN RED circuit for an open between gear position switch and reverse diode assembly If circuit is OK replace reverse diode assembly TEST E1 Power and Ground Isolation 1 Disconnect C57 starter switch and with ignition switch ON check for battery voltage at BLK LT GRN circuit If yes go to test E2 If no go to test TEST E2 Power and Ground Starte
57. t 32 ohms If yes service BLK RED circuits for an open between C315 and ECM If no replace PAIR solenoid valve Test K Engine Coolant Temperature ECT Sensor Input Test 1 Disconnect coolant temperature sensor Connect ohmmeter across sensor terminal Resistance should be less than 2k 3k ohms at 68 F 20 C and decrease with a temperature increase If yes check GRN BLK and PNK WHT circuits for an open between sensor and ECM If no replace sensor Test L Intake Air Temperature IAT Sensor Input Test 1 Disconnect C314 IAT sensor Connect ohmmeter across sensor terminal Resistance should be less than 2k 3k ohms at 68 F 20 C and decrease with a temperature increase If yes check GRN BLK and GRY circuits for an open between sensor and ECM If no replace sensor ETM 3 9 Starting System Circuit Schematic HOT IN ON HOT IN ON ETVDRTUNZSURIDBINMEDURTUTITDTMTIDTNUTMDTTURTOIMSUPTITTMTMmSTMID FUSE RELAY 1 IGN START RVE CRUISE iit FUSE AER FUSE L WHT l l 5187 e l IGN CRUISE RELAY BRN WHT WHT RED WHT l MT ee oe ee C33 C32 WHT e BLK LT GRN C11 See Engine Control System page 3 0 BANK ANGLE C57 SENSOR c92 BLK BRN LT GRN 5 COMBINATION STARTER SWITCH en REVERSE GRN Y pusH SWITCH See
58. tarting System Troubleshooting cont d 3 16 TEST B3 Reverse Lever Switch Isolation 1 Check continuity at BLK WHT circuit between reverse switch lever and reverse diode assembly If yes replace reverse lever switch If no service BLK WHT circuit for an open TEST B4 Starter Relay B Isolation 1 Reconnect any components disconnected in previous tests Disconnect C313 starter relay B connector With ignition switch ON and reverse lever in FORWARD depress starter reverse switch while checking for battery voltage at BLK starter relay A feed circuit If yes go to step 2 If no service BLK circuit for an open Depress starter reverse switch while checking for battery voltage at YEL RED circuit If yes go to step 3 If no check in line fuse B YEL RED and RED circuits for an open Depress starter reverse switch while checking for battery voltage between YEL RED and GRN RED circuits If yes go to step 4 If no go to test B5 Jumper the BLK and BLK with PNK circuits at starter relay B With gear selector in NEUTRAL and reverse lever switch in FORWARD depress starter reverse switch Starter motor should crank If yes replace starter relay B if no service BLK circuit between starter motor and starter relay B for an open TEST B5 Reverse Diode Assembly Isolation 1 Check GRN RED circuit continuity between
59. tion IGN See Ground page 2 1 CRUISE Distribution WHT RELAY page 2 8 T C73 l See Indicators asai PT 7 0 BLK LT GRN S131 RED WHT See Engine BLK BRN 1 Control System 4 INSTRUMENT Starting Syst i Founda 7 LCD J PANEL arting System rou R Bank Angle Sensor C57 16 l UNIT REVERSE a I Buio Test BLK LT GRN EC 5 cdj aLa seus ud SrTARTER PF 4 COMBINATION WHT RED WHT RED To C312 on REVERSE SWITCH page 3 26 SWITCH PUSH 5276 WHT BLU LI WHT BLU WHT BLU e 5232 YEL RED 198 YEL RED C32 YEL RED WEILIBED WHT BLU WHT RED YEL RED C57 2 Y 0 mr m n YEURED X Radio Cassette Deck WHT RED WHT BLU zen L CB Transceiver ee 11 4 dard l Start Reverse Reverse 2 0 Switch Input Indicator BLK System Start BATTERY Operation Starter Relay l Regulator Keeps Starter 1 Ground Relay A on Loe 2 REVERSE C42 CONTROL C32 UNIT GRN Solid state usu Do not check 5165 LT BLU WHT BLU 3 26 resistance C35 GRN LTBLU See Ground STARTER To 8227 Distribution RELAY 2 7 3 26 REGULATOR See Ground cue GRN i i To REVERSE SWITCH RELAY 3 25
60. tor Air Jet CAJ Solenoid Valve 3 RED Battery voltage with ignition switch ON If not go to test I 3 6 Ignition Coil Control YEL WHT Resistance to pin 2 BLK WHT is about 4 ohms If not go to test G Tachometer Output Signal YEL BLU Continuity to instrument panel connector C66 Engine Coolant Temperature ECT Sensor Input PNK WHT Resistance to GRN BLK ECM sensor common is 2k to 3k ohms at 68 F 20 C and 200 to 400 ohms at 176 F 80 C If not go to test K Pulse Secondary Air Injection PAIR Solenoid Valve BLK RED Battery voltage with the ignition switch ON If not go to test J Test A Ignition Coil Input Test Disconnect C54 Turn the ignition switch ON and place engine stop switch in RUN Check that there is battery voltage at BLK WHT ECM side of C54 circuit If yes go to test G If no service BLK WHT circuit for an open Test B ignition Pulse Generator 1 Input Test 1 Disconnect C63 and connect ohmmeter across WHT YEL and YEL circuits at generator side of connector Resistance should be about 400 500 ohms If yes check YEL GRN BLK and WHT YEL circuits between ECM and ignition pulse generators for an open If no replace ignition pulse generator Test C Ignition Pulse Generator 2 Input Test 1 Disconnect C63 and connect ohmmeter across WHT BLU and BLU circuits at generator side of connector Resistance should be about 400 500 ohms If yes check BLU GRN BLK
61. ts at ignition coil side of C54 Resistance should be about 4 ohms If OK service YEL WHT circuit between ECM and C54 for an open If not OK service ignition coil Test H Carburetor Air Jet CAJ Solenoid Valve 2 Input Test 1 Disconnect C120 CAJ solenoid valve Turn ignition ON and check for battery voltage at BLK LT GRN circuit If yes go to step 2 If no service BLK LT GRN circuit for an open Connect ohmmeter across RED WHT and BLK LT GRN circuits solenoid side Resistance should be about 32 ohms If yes service RED WHT circuits for an open between C120 and ECM If no replace CAJ solenoid valve Test I Carburetor Air Jet CAJ Solenoid Valve 3 Input Test t Disconnect C119 CAJ solenoid valve Turn ignition ON and check for battery voltage at BLK LT GRN circuit If yes go to step 2 If no service BLK LT GRN circuit for an open Connect ohmmeter across RED and BLK LT GRN circuits solenoid side Resistance should be about 32 ohms If yes service RED circuits for an open between C119 and ECM if no replace CAJ solenoid valve Test J Pulse Secondary Air Injection PAIR Solenoid Valve Input Test 1 Disconnect C315 PAIR solenoid valve Turn the ignition ON and check for battery voltage at BLK LT GRN circuit harness side If yes go to step 2 If no service BLK LT GRN circuit for an open Connect ohmmeter across BLK RED and BLK LT GRN circuits solenoid side Resistance should be abou
62. ump is a DC motor that receives ground through the GRN circuit It receives a voltage control signal from the ECM Engine Coolant Temperature ECT Sensor The engine coolant temperature ECT sensor is a resistor that increases resistance with a decrease in temperature and decreases resistance with an increase in temperature The ECT sensor sends this resistance signal to the ECM through the GRN BLK sensor common and the PNK WHT coolant temperature input circuit e Do lsolation Procedure 1 Dolsolation Procedure 2 Engine Control System Troubleshooting cont d ISOLATION PROCEDURE 1 Note Perform all checks in order If a result is incorrect go to the test referenced If a result is correct perform the next check Ground GRN Continuity to ground If not service GRN circuit for an open Sensor Common GRN BLK C49 Continuity to ECT sensor IAT sensor EON and ignition pulse generators Ignition Coil Control YEL BLU Battery voltage with ignition switch ON and engine stop switch in RUN If not go to test A 26 13 Ignition Pulse Generator 1 Input WHT YEL Resistance to GRN BLK sensor common is 400 500 ohms at 68 F 20 C If not go to test B 23 1 1 5 Lx e fea Ignition Pulse Generator 2 Input WHT BLU pem N elele Resistance to GRN BLK sensor common is 400 500 ohms at 68 F 20 C If not go
63. ured battery voltage A loss of more than one volt indicates a problem HOT AT ALL TIMES FUSE RELAY BOX LT TEST LIGHT BLU M wj H SOLENOID or VOLTMETER cont d 1 11 How To Use This Manual Troubleshooting Tests cont d Testing for Continuity This test checks for continuity within a circuit When testing for continuity at a connector you do not have to separate the two halves of the connec tor Instead probe the connector from the back Al ways check both sides of the connector because dirt and corrosion between contact surfaces can cause electrical problems 1 Disconnectthe negative cable from the battery If you are using an ohmmeter hold the leads to gether and adjust the ohmmeter to read zero ohms 2 Connect one lead of self powered test light or ohmmeter to one end of the part of the circuit you wish to test 3 Connect the other lead to the other end 4 Ifthe self powered test light glows there is con tinuity If you re using an ohmmeter low or no resistance means good continuity SELF POWERED TEST LIGHT or OHMMETER IGNITION WITCH Testing for Voltage Drop Wires connectors and switches are designed to conduct current with a minimum loss of voltage A voltage drop of more than one volt indicates a problem 1 Connectthe positive lead of a voltmeter to the end of the wire or to the side of the connector or switch closest to the batt
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