neighbourdave wrote: I have all the wiring back in place and everything is working except for the auto cancel signals. Does any one know if there is a common problem with this set up? Or any clues as to where to start looking?
I should be able to help, but it may be a bit tricky to test on the bench. I'm pretty sure that if the front wheel is not moving, it will never trigger the auto-cancel. You can sit at a stop light as long as you want with the signal on.
Do you have a way to drive the speedo cable? That would be a good first start. Maybe a drill?
I would test the solenoid in the switch housing first. My solenoid had a blown thermal fuse inside. The timing box on my bike burned up and caused the solenoid to be permanently active, at least until the thermal fuse attached to the solenoid opened up. You should be able to
briefly apply 12V directly to the solenoid wires to confirm that it's pulling in and releasing the signal selector switch.
If the solenoid checks out, I'd test the speed sensor next. This is just a simple reed switch and magnet. The sensor can be tested easily with a continuity tester (which most voltmeters have). Just connect the continuity tester across the two leads of the sensor and turn it. You should get several switch open/close transitions per revolution. I can test mine to give you exact number, but if the switch opens and closes as you turn it it is probably just fine.
The only other part is the control box, and that's just a black box filled with epoxy. You can confirm the connector contacts are in good shape, and that the input and output wires all reach their destinations, but that's it.
I believe if you activate the turn signal, and drive the speedo cable fast enough, it should kick in. If it doesn't, check the wiring and contacts again. If it still doesn't work, find a new control box.
If you need the wiring diagram, it's in the file database:
kzrider.com/filebase/search/finish/1-general/251-1000d1
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