105
NOTE: Prior to troubleshooting below, make sure
that Ignition Key Switch has not been left on with the
engine not started. After five minutes, this will deacti-
vate the EPS and display the malfunction code. Turn
Ignition Key Switch OFF and back to ON to reset and
reactivate the EPS. If code and symptom persists,
continue as follows:
1. Check 30 amp EPS fuse.
2. Check EPS relay (may be switched with any other
4-pin relay on PDM - replace relay if EPS normal
after switching).
3. Disconnect 2-pin connector on the EPS assembly
and connect a volt meter set to DC voltage to the har-
ness (black meter lead to BLK and red meter lead to
ORG/BRN) With the ignition switch to the ON posi-
tion, the meter must read more than 8.5 DC volts (if
correct voltage is not present, check connections and
wiring harness - if correct voltage is present, replace
EPS assembly - see Steering/Frame/Controls - Steer-
ing Post/Tie Rods sub-section).
Condition: Ignition switch ON and EPS assist normal
when moving handlebar. Code “P0635” flashing.
NOTE: Prior to troubleshooting steps below, make
sure that the Engine Stop Switch has not been used
to stop the engine leaving the ignition switch in the
ON position. If the engine stop switch is not in the
RUN position, set to RUN position and cycle the igni-
tion switch to OFF then ON. If malfunction code is
still indicated, proceed as follows.
1. Check for speed sensor signal by disconnecting the
8-pin connector from the EPS assembly and using a
multi-meter set to the DC volt position, connect the
black lead to the PNK/YEL wire and the red lead to
the ORG wire. With the ignition switch turned to the
ON position, slowly move the vehicle forward or
backward. The meter must alternate from 0 DC volts
to approximately 12 DC volts. If meter readings are
not as specified:
A. Check EPS diode for correct installation or open
diode (replace diode or install correctly).
B. Check speed sensor using procedure found in this
section (replace speed sensor/install proper
gauge).
2. Check for engine speed signal by disconnecting the
8-pin connector from the EPS assembly and using a
multi-meter set to the AC voltage position, connect
one lead to any BLK wire and the other lead to
YEL/VLT wire. Start the engine and with the engine
idling the meter should read approximately 7.5 AC
volts. If meter reading is not as specified:
A. Check the wiring harness from EPS to gauge
(YEL/VLT wire - repair wiring).
B. Check the AC generator using the Stator
Coil/Crankshaft Position (CKP) Sensor procedure
found in this section. If not to specifications,
replace the stator coil.
If after completing the above checks with normal results
and malfunction code “P0635” persists, the EPS assem-
bly must be replaced. To replace the EPS assembly, see
Steering/Frame/Controls - Steering Post/Tie Rods.
Ignition Switch
The ignition switch harness connects to the switch with a
four-pin connector. To access the connector, remove the
ignition switch nut, remove the switch, and press the con-
nector release tab. Pull the connector from the switch.
CF272A
CF273A
VOLTAGE
NOTE: Perform this test on the harness connector.
1. Set the meter selector to the DC Voltage position.
2. Connect the red meter lead to either red wire; then
connect the black meter lead to ground.
3. Meter must show battery voltage.
NOTE: If the meter shows no battery voltage, trou-
bleshoot the battery or the main wiring harness.
RESISTANCE
NOTE: Perform this test on the switch using the fol-
lowing procedure.
CAUTION
Do not attempt to check resistance of the EPS motor
(2-pin input receptacle). There are internal capacitors
holding a charge that can cause internal damage to an
ohmmeter.
