Kawasaki J300 - Service manual > Switches and Sensors

Brake Light Timing Inspection

• Refer to the Brake Light Switch Operation Inspection in the Periodic Maintenance chapter.

Switch Inspection

• Using a tester, check to see that only the connections shown in the table have continuity.
  • For the switch housings and the ignition switch, refer to the tables in the Wiring Diagram.

  If the switch has an open or short, repair it or replace it with a new one.

Side Stand Switch Connections

Oil Pressure Switch Connections*

*: Engine lubrication system is in good condition.

Water Temperature Sensor Inspection

• Remove:
  Water Temperature Sensor (ECU) (see Water Temperature Sensor (ECU) Removal in the Fuel System (DFI) chapter)
  Water Temperature Sensor (Meter) (see Water Temperature Sensor (Meter) Removal in the Cooling System chapter)
• Suspend the sensor [A] in a container of coolant so that the temperature-sensing portion [C] is submerged.
• Suspend an accurate thermometer [B] with temperature-sensing portion located in almost the same depth with the sensor.

NOTE

• The sensor and thermometer must not touch the container side or bottom.

 

• Place the container over a source of heat and gradually raise the temperature of the coolant while stirring the coolant gently.
• Using the digital meter, measure the internal resistance of the sensor.

  If the digital meter does not show the specified values, replace the sensor.

Water Temperature Sensor (ECU) Resistance

Water Temperature Sensor (Meter) Resistance

Fuel Level Sensor Inspection

• Remove the fuel pump (see Fuel Pump Removal in the Fuel System (DFI) chapter).
• Connect a digital meter to the fuel pump connector.
• Measure the fuel level sensor resistance.

Fuel Level Sensor Resistance
 Connections:
  Y/W lead terminal [A] ← → BL/W lead terminal [B]
 Standard:
  Full Position [C] 1100 +-33 Ω @20ºC (68ºF)
  Empty Position [D] 100 +-3 Ω @20ºC (68ºF)

If the tester does not read as specified, replace the fuel pump.

Speed Sensor Removal/Installation

• Refer to the Front Rotation Sensor Removal/Installation in the Brakes chapter.

Speed Sensor Inspection

• Refer to the Wheel Rotation Sensor Inspection in the Brakes chapter.

Oxygen Sensor Removal

• Remove the storage box (see Storage Box Removal in the Frame chapter).
• Disconnect the oxygen sensor lead connector [A].

NOTICE Do not pull strongly, twist, or bend the oxygen sensor lead. This may cause the wiring open.

• Remove the oxygen sensor [A].

Oxygen Sensor Installation

NOTICE Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] to prevent oil contact. Oil contamination from hands can reduce sensor performance.

• Tighten:
  Torque - Oxygen Sensor: 25 N*m (2.5 kgf*m, 18 ft*lb)
• Run the oxygen sensor lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Oxygen Sensor Inspection

• Refer to the Oxygen Sensor Inspection in the Fuel System (DFI) chapter.

Oxygen Sensor Heater Inspection

• Refer to the Oxygen Sensor Heater Resistance Inspection in the Fuel System (DFI) chapter.

Side Stand Switch Removal

• Remove the left side fairing (see Side Fairing Removal in the Frame chapter).
• Disconnect the side stand switch lead connector [A].
• Remove:
  Band [B]
  Bolt [C]
  Side Stand Switch [D]

Side Stand Switch Installation

• Installation is the reverse of removal.
• Insert the projection [A] of the side stand switch into the hole [B] of the side stand.

Side Stand Switch Inspection

• Refer to the Switch Inspection.

Relay Inspection

• Remove the front fairing (see Front Fairing Removal in the Frame chapter).
• Disconnect the relay connectors, and remove the relays.

  Fan Relay [A]
  Starter Relay 1 [B]
  High Beam Headlight Relay [C]
  Low Beam Headlight Relay [D]
  ECU Relay [E]
  Fuel Pump Relay [F]

NOTE

• The fan relay, starter relay 1, high beam headlight relay, low beam headlight relay, ECU relay and fuel pump relay are the same.

• Connect a tester [A] and 12 V battery [B] to the relay [C] as shown.

  If the relay does not work as specified, the relay is defective.

  Replace the relay.

Testing Relay
 Criteria:
  When battery is connected → about 0 Ω
  When battery is disconnected → ∞ Ω

Fuse

Fuse Box Fuse Removal

• Remove the battery cover (see Battery Removal).
• Unlock the hooks [A] to remove the lid.

• Pull the fuses [A] straight out of the fuse box with needle nose pliers.

Fuse Installation

If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.

• Install the fuse box fuses on the original position as specified on the lid.

Fuse Inspection

• Remove the fuse (see Fuse Box Fuse Removal).
• Inspect the fuse element.

  If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.

  Housing [A]
  Fuse Element [B]
  Terminals [C]
  Blown Element [D]

NOTICE When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit.

Installation of a fuse with a higher rating may cause damage to wiring and components.

See also: