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[jefrs]

We cross posted. Whew!

However put my spade connectors on had a strong grip, they're very well connected but the spade/connector quality is on the wee bit thin and not very springy side. Most connectors aren't simple spades though, they're blocks. The casquette is a very tight fit and hence a suspect area.

The little lamp bulbs I had issue with hardly fitted their sockets they were that poor, pathetic pins. They are standard car bulbs, forgotten the number but there are two power ratings, it's the smaller one. The "Warning Indicator Unit" prises out on the paint tin opener screwdriver, mind the paint, a squirt of silicone oil eases it. Car fuses at the same emporium but there are two look-alike size bodies. Take the old parts with you.

[jefrs]

I was wrong, there are four fuses on the 2014/15 Classic 500 EFi - 15A Main and 3x10A ECU, Light and Aux, plus two spares in the empty slots (and a bag full below).



Problem with the Autotune AT-200 is the wide-range O2 sensor is M18 and the hole is M12 narrow-range. It don't fit. My welding capability is genuine birdshit rubbish, I don't weld, I do braze and hard solder. Dynojet are looking into a solution for me, thank you Dynojet UK.

[jefrs]

Pic of fuses, not colour code, l to r 10, 10, 10, 15 (current C5)

[jefrs]

tpyos, there's a good word for that but I'll not use it here - the semi-auto spelling checker chooses the wrong worms, "note colour code".

[rog]

Jefrs,thanks for the additional info and photo. My B5 model (ie the one that looks like an old 350) definitely has only three 20amp fuses as shown in Scalyback/Thackery drawings. I haven't had time to look at the bike today but once I've repaired the rear light cluster wiring I'll delve further into the casquette wiring and connectors.

[Thack]

It's tricky doing those wiring and circuit diagrams, because RE change the wiring every so often without the changes necessarily being obvious.



Scalyback's wiring diagram - upon which I based the circuit diagrams - is for the 2011 model, and my 2014 model is different in having four fuses instead of three. Having said that, I've found it close enough to be very useful when working on my own bike.



I don't think our wiring/circuit diagrams have any fuses in series, which I agree would be most unusual. The only time current flows through two fuses in series is in the charging circuit (p13 of the wiring/circuit diagram document). However, appearances are deceptive, as they are actually in parallel and protecting two different items.



Remember that when the bike is running, there are two potential sources of current to the wiring loom: the battery, and the rectifier/regulator. These are connected in parallel and both can feed the loom. Therefore, if a short circuit occurs in the wiring loom you need to protect both sources against excessive current. Hence each source has its own fuse. A side effect is that the charging current flows through both fuses - i.e. out of the rectifier, through the rectifier fuse, then through the battery fuse and finally into the battery.

[jefrs]

Thack, yours and Scaleyback's diagrams seem reasonably accurate, good enough for diagnostics. The only RE diagram I've found to be accurate is in the "Classic 500 owners manual - Feb 2012.pdf" which confusingly is the revised and corrected version for the current model. I described the current flow from the battery as is my wont, considering the generator solely as the device charging it. Why do that? - because when testing, it will probably be running on the battery with the motor stopped. The main fuse is on the charging circuit between alternator/regulator and battery. It is often easier to break a circuit down into sub sections because it is easier to visualise.

It's quite difficult to describe a circuit diagram unambiguously in words. Thanks for the work on the diagrams

[Scalyback]

Jefrs having checked the newer diagram (2014), it seems that ECU pins 7 & 17 are not mentioned and that the O2 sensor has been deleted from the design? Or am I looking at the wrong (not UK) diagram)?



Clicking on the pic below takes you to tinypic, where you can right click and save as which should get you a large copy.

[center]




I can't check till I posted so if it doesn't work, I'll fix it in a post below.

[Scalyback]

[center]


Of course it didn't!

TAKE 2!

[jefrs]

Scalyback - that diagram has two spark plugs so it's for the Twin Spark. It also shows two horns. I can't actually read it unless I greatly enlarge it. To be honest I was only interested in the top half of the circuit and did not check the ECU section. In my paper owners manual RE provided three diagrams, the complete circuit is about A6 size but does show "O2 Sensor" between coil and K-Line on pins 7, 17 and 25 and ground (black). I had to use a big hand glass to see that. The diagrams in that booklet only show Main Fuse and ECU Fuse (both 20A) but the "Classic 500 owners manual - Feb 2012.pdf" does show the correct fuses correctly. There is also a "Classic 500 owners manual - Feb 2012-India.pdf". It beggars the question what the devil are RE working to as a circuit diagram?



Would it help if I scanned the paper owners manual and post it here?