Failed MOT

[shmirsh]

Hi Guys

Bike's been standing in garage for 2 years and wanted to get it MOT'd for sale. Don't use it at all as have a new toy. 2 problems on MOT , back brake switch and main beam switch.

1. Fitted new back brake switch but the front indicator lights stay on. Any thoughts?
2. Main beam switch sticks sometimes. Tried WD40, which worked for 10 minutes! How easy to dismantle and fix?

Bike is 1996 CBR400RR NC29. Suggestions greatly appreciated
Shahid

[Davez29]

Regarding the switch, it is easy but fiddly to take apart as there is a couple of small parts and a spring.

So, open the switchgear, remove the screws to the cable and small white box, carefully unclip the base of the white box carefully opening it (watch the spring does not go into orbit) try keeping a finger over the inside of the button this will keep the spring from flying out.

Once you have this box and the contents free, move over to a safe area where you can take it apart. you will find the spring, two pieces of copper wire and a flattened N shape piece of copper, chances are this N shaped wire is not lying corrctly in the plastic grooves or its really dirty. I cant really tell you how to put this in but look at the grooves in the plastic and this will guide you where it lies upright, basicly one bottom left pin on the N in a hole, the right top pin of the N between the button guides, if that makes sense? sorry I can do it easy but describing it seems a tad harder. put the switch and spring back in place and try it out, if done right the button should click in and out with ease. There is also a possibility the leaf contacts have moved, one lies flat the other is central in a springy way to help the switch keep in place. Finally there is 4 small contacts on the button, make sure these move freely, possibly even taking them apart carefully and reforming the contacts as the tend to sink inwards spoling any contact to be made.

Do you have to have a high beam for the MOT?

[tanuki]

Do the idicators have 3 wires going to them?

[shmirsh]

Thanks for coming back so quickly.
I'll take the swtich apart over the weekend and post my findings. Yes I do have main beam.
Just remembered following, which you probably know:
- it's an import
- both headlights always come on when ignition is turned on (left dipped beam filamet has blown so only works on main)
- main beam works on both headlights
- rear lights also on
- rear plate light is built into rear lights MOT says this does not work but it does as it's always on

Do the idicators have 3 wires going to them?

What do I need to check if there are three wires? Also what should I look for if there are < 3?

One further request, is there an online workshop manual and/or wiring diagrams that I can view?

Shahid

[tanuki]

Look where the conectors are by the headlights and count the wires.

Some eu countries and the USA have a law that your indicators have to be on all the time and I thought this might be the reason for yours being stuck on as I once had a 29 with this issue.

[Davez29]

Yeah the 1994 R model has these extra wires for the side lights and you cant turn your headlights off. Unfortunatly the last owner of my bike put horrible tiny led indicators on and cut the wires off. I replaced them with earlier nc29 indicators but dont have the sidelights now. The 3 wires are all together near the outer part of the nose fairing on each side. The only online parts manual is at CSMNL.com

here is a wiring diagram for the R model. http://i56.tinypic.com/a43qqt.jpg

[shmirsh]

Thanks again guys.

Look where the conectors are by the headlights and count the wires.

Some eu countries and the USA have a law that your indicators have to be on all the time and I thought this might be the reason for yours being stuck on as I once had a 29 with this issue.

I did notice loose connectors inside front fairing. I pushed them back together but did not see anything at the time because the battery was off. Only found that the indicator lights were on when I had fitted the rear brake switch and put battery back.

And yes, I can't turn the healights off. That said, it's been a bonus because people see me coming.

Shahid

[shmirsh]

FYI, I get an error on http://www.CSMNL.com website.

[Davez29]

Have you not connected the indicator side lights? If so its quite normal for the R model but I believe its illegal so importers disconnect them. use the wiring diagram to determine the set up you have. If you have, put an indicator on, the sidelights will then go out and they should indicate as normal. I like the idea of headlights on, as I have them, but the thing is your battery don't last two long if your mucking about with the ignition on, especially if you have done the mod to use Philips Extreme bulbs. In that instance I always pull the bulb connecters.

BTW, the indicator side lights are normally called running lights as in the wiring diagram above.


Try this link.. http://www.cmsnl.com/honda-cbr400rr_model17061/