Kawasaki J300 - Service manual > Lighting System

Headlight Aiming Inspection

• Refer to the Headlight Aiming Inspection in the Periodic Maintenance chapter.

Headlight Bulb Replacement

• Remove:
  Front Fairing (see Front Fairing Removal in the Frame chapter)
  Dust Cover [A]

• Disconnect the headlight connector [A].
• Release the hook [B].
• Remove the headlight bulb.

NOTICE When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.

NOTE

• Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution.

 

• Replace the headlight bulb with a new one.
• Fit the projections [A] of the bulb in the hollows [B] of the headlight.
• Install the hook.

• Connect the headlight connector.
• Install the dust cover [A].
• After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).
  • Other Bulb: Repeat the above steps.

Headlight Removal/Installation

• Refer to the Front Fairing Disassembly/Assembly in the Frame chapter.

Tail/Brake Light (LED) Removal/Installation

• Refer to the Rear Fairing Disassembly/Assembly in the Frame chapter.

License Plate Light Bulb Replacement

• Remove:
  License Plate Light Cover Screws [A]
  License Plate Light Cover [B]

• Pull the bulb [A] out of the socket [B].

NOTICE Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage than the specified value.

• Replace the bulb with a new one.
• Install the license plate light cover, and tighten it screws.

Headlight/Tail Light Circuit

1. Left City Light (LED)
2. Left Headlight 12 V 33 W/35 W
3. Right Headlight 12 V 33 W/35 W
4. Right City Light (LED)
5. Meter Unit
6. Blue High Beam Indicator Light (LED)
7. Front Brake Light Switch
8. Fuse Box
9. Main Fuse 15 A
10. Charging/ECU Fuse 30 A
11. Headlight Relay Fuse 15 A
12. Ignition Switch
13. Battery 12 V 10 Ah
14. Engine Ground
15. Frame Ground 1
16. Tail/Brake Light (LED)
17. Hazard Control Unit
18. Dimmer Switch
19. Rear Brake Light Switch
20. Low Beam Headlight Relay
21. High Beam Headlight Relay

Turn Signal Light Bulb Replacement

Front Turn Signal Light

• Remove:
  Front Fairing (see Front Fairing Removal in the Frame chapter)
  Front Turn Signal Light Socket Screws [A]
  Front Turn Signal Light Socket [B]

• Push and turn the front turn signal light bulb [A] counterclockwise and remove it.
• Replace the bulb with a new one.

• Insert the new bulb [A] by aligning the pins [B] with the grooves [C] in the socket, and turn the bulb clockwise.
• Install the front turn signal light socket, and tighten its screws.
  • Other Bulb: Repeat the above steps.

Rear Turn Signal Light

• Remove the rear fairing (see Rear Fairing Removal in the Frame chapter).
• Turn the socket [A] counterclockwise and pull out the socket together with the bulb.

• Push and turn the rear turn signal light bulb [A] counterclockwise and remove it.
• Replace the rear turn signal light bulb with a new one.
  • Replacement procedure of the rear turn signal light bulb is common with it of the front turn signal light bulb.

• Fit the large projection [A] of the socket into the large groove [B] of the turn signal light.
• Turn the rear turn signal light bulb clockwise.

Turn Signal Relay Inspection

• Remove the front center cover (see Front Center Cover Removal in the Frame chapter).
• Pull out the turn signal relay [A] backward, and remove it from the rear fender.
• Disconnect the connector.

• Connect one 12 V battery and turn signal lights as indicated, and count how many times the lights blink for one minute.

  Turn Signal Relay [A]
  Turn Signal Lights [B]
  12 V Battery [C]

Connections:
 Battery (+) → BK lead terminal
 Turn Signal Lights → GY lead terminal

If the lights do not blink as specified, replace the turn signal relay.

Testing Turn Signal Relay

(*): Cycle(s) per minute
(**): Corrected to "one light burned out".

Hazard Control Unit Removal

• Remove the rear fairing (see Rear Fairing Removal in the Frame chapter).
• Disconnect the connector [A].
• Remove the hazard control unit [B].

Hazard Control Unit Installation

• Installation is the reverse of removal.

Hazard Control Unit Inspection

• Turn the ignition switch on.
• Turn the hazard switch on.
• The left and right turn signal lights (front and rear) should blink.

  If turn signal light does not blink, inspect or replace the following parts.

  Turn Signal Light Bulbs (see Lights and witches Operation Inspection Periodic Maintenance chapter)
  Harness (see Wiring Inspection)
  Ignition Switch (see Wiring Diagram)
  Hazard Switch (see Wiring Diagram)
  Main Fuse 15 A (see Fuse Inspection)
  Charging/ECU Fuse 30 A (see Fuse Inspection)

If all items are good condition, replace the hazard control unit (see Hazard Control Unit Removal/Installation).

Turn Signal Light Circuit

1. Front Left Turn Signal Light 12 V 10 W
2. Front Right Turn Signal Light 12 V 10 W
3. Green Left Turn Signal Indicator Light (LED)
4. Green Right Turn Signal Indicator Light (LED)
5. Meter Unit
6. Hazard Switch
7. Fuse Box
8. Main Fuse 15 A
9. Charging/ECU Fuse 30 A
10. Ignition Switch
11. Battery 12 V 10 Ah
12. Engine Ground
13. Frame Ground 1
14. Rear Right Turn Signal Light 12 V 10 W
15. Rear Left Turn Signal Light 12 V 10 W
16. Hazard Control Unit
17. Turn Signal Switch
18. Turn Signal Relay

Storage Box Light/Storage Box Light Switch Removal

• Remove:
  Storage Box (see Storage Box Removal in the Frame chapter)
• Cut the band [A]
• Disconnect:
  Storage Box Light Lead Connectors [B]
• Remove:
  Lock Nuts [C]
  Storage Box Light [D]
  Storage Box Light Switch [E]

Storage Box Light/Storage Box Light Switch Installation

• Installation is basically the reverse of removal.
• Run the storage box light and storage box light switch leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Storage Box Light System Inspection

NOTE

• Be sure the battery is fully charged.

 

• Open the seat.

  If the storage box light [A] does not go on, check the storage box light (see Storage Box Light Inspection).

  If the storage box light goes on, continue the next procedure.

• It will light off 2 minutes later while opening the rider seat.
• It will light off 3 seconds later while masking the sensor below 4 cm.

  If the above storage box light system does not work, replace the storage box light switch [A].

Storage Box Light Inspection

• Check the charging/ECU fuse [A] 30 A (see Fuse section).

  If the fuse is good, remove storage box (see Storage Box Removal in the Frame chapter).

• Disconnect the storage box light lead connectors [A] and using the auxiliary leads, connect the 12 V battery to the storage box light lead connectors as follows.

• Connect the battery positive (+) terminal to the green/red lead.
• Connect the battery negative (-) terminal to the green lead.

If the storage box light [A] does not go on, replace the storage box light.

If the storage box light goes on, check the storage box light switch (see Storage Box Light Switch Inspection).

• Connect the storage box light lead connectors.

Storage Box Light Switch Inspection

• Check the input voltage of the storage box light switch at the lead connectors [A] of main harness side.

• Connect the voltmeter [A] to the storage box light switch lead connectors as follows.

  Main Harness Side [B]

  • Connect the voltmeter positive (+) terminal to the red/white lead.
  • Connect the voltmeter negative (-) terminal to the green lead.

  If the reading is not the battery voltage, check the wiring for continuity according to the Storage Box Light System Circuit.

  If the reading is the battery voltage, replace the storage box light switch.

Storage Box Light Circuit

1. Charging/ECU Fuse 30 A
2. Battery
3. Engine Ground
4. Storage Box Light Switch
5. Storage Box Light

Radiator Fan System

Fan Motor Inspection

• Remove the right side fairing (see Side Fairing Removal in the Frame chapter).
• Disconnect the radiator fan lead connector [A].
• Using an auxiliary leads, supply battery power to the fan motor.

  If the fan does not rotate, the fan motor is defective and must be replaced.

Radiator Fan Circuit

1. Engine Stop Switch
2. Fuse Box
3. Ignition Fuse 10 A
4. Charging/ECU Fuse 30 A
5. Ignition Switch
6. Fan Relay
7. Side Stand Switch
8. Battery 12 V 10 Ah
9. Engine Ground
10. Frame Ground 1
11. ECU Relay
12. ECU
13. Water Temperature Sensor (ECU)
14. Fan Motor
15. EMI Filter

See also: