Experiment-4:
Aim: Study of lighting systems.
Lighting System and Circuit of Two-Wheeler: The basic purpose of the lighting system in
motorbike is to provide illumination for the driver to operate the bike safely after dark and to
increase the conspicuity of the motorbike.
The lighting system of a motor vehicle consists of lighting and signalling devices mounted or
integrated to the front and rear. The lighting system display information about the vehicle's
presence, position, size, direction of travel, and driver's intentions regarding direction and speed
of travel.
It may be desirable for motorcycles in mixed traffic to have conspicuity that is equivalent to that
of automobiles. However the narrow frontal area and irregular outline of a motorcycle make it
more difficult to recognize the whole body of a motorcycle than that of an automobile. Lighting
system enhances the conspicuity of motorcycles by enhancing the ability of oncoming drivers to
judge both the distance and speed of a motorcycle.
Locations of components of lighting system
The locations of different components of lighting system of typical motorbike are shown in the
Fig.L-1. These components are as per circuit diagram shown in Fig.
1. Main switch
4. Start switch
7. Fuse main
8. Battery
37. Indicator light front
40. Indicator light front
49. Fuse box
50. Dimmer light switch
51. Meter lights
52. High beam indicator light
53. Head light
54. Tail light
55. License plate light
The typical circuit diagram as shown in Fig. L-2 is for the all the systems of the motorbike.
However the components which form the lighting system of the bike are mentioned above. The
students will notice that in the circuit diagram the components such as headlight are joined by
the wires to the different switches which are operated by the driver of the bike. Therefore the
driver operates different switches for sending the signal/current to different components. For
turning the bike the driver will operate indicator switch which will send the current to flasher unit
and indicator lamps.
Basic lighting circuit: The simplified and basic lighting circuit is shown in Fig.L-3 and consists
of battery, head light, tail/rear light, brake light and pilot light connected through wires from the
switches which are operated by the driver of the bike.
Fig. L-2 and L-3 shows that the lighting circuit consists basically of various switches, lamps,
wires and fuses connected to battery. The switches are mounted on the handle bar of the
motorbike and operated by the driver. For the repair and maintenance the Auto Electrician has
to check switches whether they are functional, check the continuity of wires between switches
and lamps and also check the lamps.
The manufacturer of the bike provides an owners manual which contains all the technical
specifications and electrical circuit diagrams (a typical circuit diagram is shown in Fig.L-2). The
circuit diagrams provide information about various electrical systems such as lighting system,
starting system, charging system, ignition system etc.
Switch Connection as Shown in Manual: The manual contains a connection chart as shown
in Fig. L-4. It shows the terminal connections of the switches (e.g., main switch, handlebar
switch, brake switch, lighting switch, etc.) The extreme left column indicates the switch positions
and the top line indicates the colours of leads connected with the terminals in the switch
component.
indicates the terminals between which there is a continuity of electricity; i.e., a closed
circuit at the respective switch positions.
In this Fig. L-4 :
“R and Br” and “L/W and L/R” are continuous with the “ON” switch position.
“B and B/W” is continuous with the “OFF” switch position.
“B and B/W” is continuous with the “LOCK” switch position.
“B and B/W” and “R and L/R” are continuous with the “P” switch position.
Various switches and switch connections of a typical bike are shown in Fig. L-5
Checking Switch Continuity: The continuity of each switch can be checked with the
multimeter. If the continuity reading is incorrect, check the wiring connections and if necessary,
replace the switch. The continuity reading should be as per owners manual.
Set the multimeter to “0” and to the “Ω × 1” range.
As shown in Fig. L-6, insert the probes of the multimeter in the connection terminals as per
owners manual. The example is shown in the Fig.
When checking for continuity, switch back and forth between the switch positions a few
times.
The example illustration shows that:
There is continuity between blue/red and red when the switch is set to “ ”.
There is continuity between blue/red and blue, between brown/blue and red, and between
blue/yellow and black when the switch is set to “ON”.
Lamps/Lights
The motorcycle has a head light, tail light, indicator lamps in the front and rear, meter lights and
some models may have other accessories lights also. Headlight does two important things. It
helps to see what is in front when riding in dark and dim environments and drivers of other
vehicle can also see the motorcycle on the road. As shown in the Fig. L-7, the headlight
consists of a reflector, a bulb mounted in the centre of the reflector, glass and body of the light.
The bulb is usually of 55w/65w halogen bulbs or Xenon charged halogen bulbs which are
considerably brighter. LED lamps have become more common now a days as they consume
less power and provide better illumination.
Tail or rear light is fitted in the rear of the bike. It is multifunctional light . When the driver of the
bike applies brake the light illuminates and the following vehicle can notice the same and lower
the speed. Similarly during the night or in foggy days, it is switched on for providing conspicuity
to the bike.The wattage may be 21 for stop light and 5 for tial light . A typical tail light is shown in
Fig. L-8.
Indicator lights are very important in bike or in any automobile. The bike may need turning on
the crossings to the left or right and accordingly the drivers operate the indicator switch. It gives
signal to the front coming and following rear vehicles that bike will either turn to the left or right.
There are two indicator lamps in the front and two in the rear of the bike. The indicator lamps of
one side (left or right)in the front and rear blinks or flashes continuously on operating the
indicator light switch. The indicator switch is switched off after the driver of the bike has
completed the turn and is following the straight path. There is a self cancelling system in some
bikes in which the indicator switch is turned off automatically when the steering becomes
straight position. The indicator lamp can have wattage of 21 and the lamps are shown in Fig. L-
9.
Turn Signal/Hazard Relay Circuit
A typical turn signal and hazard relay wiring diagram is shown in Fig. L-10. In the diagram turn
signal and hazard switches are in the “Off” position. When the turn signal switch is turned on
(either left or right), power flows from the battery, through the turn signal relay, through the left
or right switch contacts, and through the left or right indicator and signal lights to ground. When
the hazard switch is activated, power flows from the battery, through the hazard switch contacts,
and through both the left and right indicator and signal lights to ground. The hazard relay and
turn signal relay are special circuits that open and close to make the lights flash.
Headlight Relays
Relays can help increase the life of a motorcycle headlight bulb and switchgear. An electrical
relay is basically a remotely controlled switch that's turned on and off by the normal headlight
switch. When a relay is wired into the motorcycle's headlight wiring harness, the motorcycle's
handlebar switch sends an electrical impulse to the relay, and the relay clicks on and sends
power to the headlight directly from the battery. Thus headlight relay select high or low beam on
headlight with a single button switch. It allows the headlight to be controlled from the handlebars
without using a large rocker-style switch. The relay is shown in Fig.
Brake-Light Circuit
A typical brake-light circuit is shown in Fig.L-12. In the figure there are two separate brake-light
switches, one for the front brake and one for the rear brake. The brake switch is activated by
applying the brakes. On application of brakes, the circuit is completed and the brake light is
illuminated. The ignition switch in the brake-light circuit keeps the brake light from operating
except when the ignition switch is turned on.
Types of Bulbs
The bulbs used on the motorcycle are shown in Fig. L-13. Bulbs A and B are used for headlights
and usually use a bulb holder which must be detached before removing the bulb. The majority
of these bulbs can be removed from their respective socket by turning them counterclockwise.
Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by
pushing and turning the bulb counterclockwise. Bulbs D and E are used for meter and indicator
lights and can be removed from their respective socket by turning (D) and pulling (E).
Testing of Bulbs
Two types of bulbs are shown in Fig. L-14 having different types of pins for holding the bulbs in
holders. The bulb can be visually inspected for broken filaments. However if the filaments are in
their places and bulb does not light, it should be checked by multimeter. It is assumed that the
current is reaching in the bulb holder. The procedure for testing the bulbs with the ultimeter is as
below (refer to Fig. L-14).
1. Set the multimeter to the resistance mode for checking the continuity.
2. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2,
and check the continuity.
3. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3,
and check the continuity.
4. If either of the readings indicates no continuity, replace the bulb.
a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2,
and check the continuity.
b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3,
and check the continuity.
c. If either of the readings indicates no continuity, replace the bulb.
ELECTRICAL
ELECTRICAL COMPONENTS
TYPES OF BULBS
The bulbs used on this motorcycle are shown in the illustration on the left.
_ Bulbs A and B are used for headlights and usually use a bulb holder which must be detached
before removing the bulb. The majority of these bulbs can be removed from their respective
socket by turning them counterclockwise.
_ Bulb C is used for turn signal and tail/brake lights and can be removed from the socket by
pushing and turning the bulb counterclockwise.
_ Bulbs D and E are used for meter and indicator lights and can be removed from their
respective socket by turn D and pulling E them out.
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
_ Before checking for continuity, set the multimeter to “0” and to the “Ω × 1” range.
_ When checking for continuity, switch back and forth between the switch positions a few times.
NOTE:
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an
illustration similar to the one on the left. The switch positions (a) are shown in the far left column
and the switch lead colors (b) are shown in the top row in the switch illustration. “ ”
indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the
respective switch position).
The example illustration on the left shows that:
There is continuity between blue/red and red when the switch is set to “Pε”.
There is continuity between blue/red and blue, between brown/blue and red, and between
blue/yellow and black when the switch is set to “ON”.
The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an
illustration similar to the one on the left. The switch positions (a) are shown in the far left column
and the switch lead colors (b) are shown in the top row in the switch illustration. R Br Gy,
NOTE: @
“ ” indicates a continuity of electricity between switch terminals (i.e., a closed
circuit at the respective switch position).
The example illustration on the left shows that: There is continuity between red and brown
when the switch is set to “ON”.
Fig. L-6 Checking switch
continuity
SWITCH CONNECTION AS SHOWN IN
MANUAL
The manual contains a connection chart as shown left showing the terminal connections of the
switches (e.g., main switch, handlebar switch, brake switch, lighting switch, etc.) The extreme
left column indicates the switch positions and the top line indicates the colors of leads
connected with the terminals in the switch component.
indicates the terminals between which there is a continuity of electricity; i.e., a cl.osed
circuit at the respective switch positions.
In this chart: “R and Br” and “L/W and L/R” are continuous with the “ON” switch position.
“B and B/W” is continuous with the “OFF” switch position.
“B and B/W” is continuous with the “LOCK” switch position.
“B and B/W” and “R and L/R” are continuous with the “P” switch position.
