BATTERY, LIGHTING SYSTEM, HORN
Paragraph
Description 112
Battery 113
Headlights 114
Taillights 115
Ignition and light switch 116
Horn 117
Wiring 118
112. DESCRIPTION.
=a.= Lighting system and horn are supplied 6‐volt current from the
22‐ampere‐hour battery. Negative side of battery and system is
grounded. Blackout lights and service lights are controlled by the
same switch (ignition and light switch) which also controls ignition.
Blackout headlight has auxiliary control switch in body. Service
headlight upper and lower beam is controlled by toggle switch on
left handle bar. Horn is operated by button on left handle bar after
ignition and light switch is in “ON” position. Blackout stop light and
service stop light are operated by brake foot pedal switch.
113. BATTERY.
=a.= The 3‐cell, 15‐plate, 6‐volt, 22‐ampere‐hour battery is located
in battery box back of frame seat post tube, and is accessible for
inspection and or service after removing box cover. Normally charged
battery has specific gravity reading of 1.275. Normally discharged
battery has specific gravity of 1.150.
=b. Check Electrolyte Level= (fig. 74).
(1) Raise saddle and bar assembly after releasing and removing swivel
pin.
(2) Loosen wing thumb nuts on box top hold‐down studs sufficiently to
disengage bracket slots, then lift off box cover.
(3) Remove the three filler plugs. Check and or adjust electrolyte
level. See that electrolyte level is 5/16 inch above plates. If
necessary, bring electrolyte to that level, using clean, drinkable
water.
(4) Clean top of battery before installing box cover.
(5) Clean terminals or posts, if corroded. Make sure that the felt
washers are on posts and are saturated with engine oil.
=c. Remove Battery.= Raise saddle and bar assembly. Release and
remove swivel pin. Loosen wing thumb nuts on box top hold‐down studs
sufficiently to disengage bracket slots, then lift off box cover.
Disconnect positive and negative wires from battery terminals. Lift
battery upward out of battery box.
[Illustration: RA PD 310278
_Figure 73—Complete Wiring Diagram_
1. SWITCH TERMINAL (Three Wires connected)—=Black= wire from
blackout marker light 24; taillight cable =green= wire from
blackout taillight 22; single wire direct from blackout headlight
as shown by dotted line in illustration 43, or horn and headlight
cable =black= wire from junction terminal 35 as shown in
illustration 44.
2. SWITCH TERMINAL (Four wires connected)—Generator and relay
cable =green= wire from “=switch=” terminal (14) of
generator; taillight cable =black= wire from service stop
and taillight (23); horn and headlight cable =red= wire from
junction terminal 17; =black= wire from speedometer light (11).
3. SWITCH TERMINAL (Two wires connected)—Generator and relay cable
=red= wire from terminal marked “BAT” on relay; coil and
battery cable =red= wire from junction terminal 18.
4. SWITCH TERMINAL (One wire connected)—=Black= wire from oil
signal light terminal (10).
5. SWITCH TERMINAL (One wire connected)—Taillight cable
=yellow= wire from blackout stop lamp (21).
6. SWITCH TERMINAL (One wire connected)—Battery and coil cable
=black= wire from junction terminal 19.
7. SWITCH TERMINAL (One wire connected)—Taillight cable =red=
wire from service stop and taillight (23).
8. GENERATOR SIGNAL LIGHT TERMINAL (One wire connected)—Generator
and relay cable =black= wire from relay right front terminal.
9. OIL PRESSURE SIGNAL LIGHT TERMINAL (One wire
connected)—=Black= wire from oil pressure switch (16).
10. SIGNAL LIGHT TERMINAL (Four wires connected)—=Black= wire
(under switch panel) from generator signal light terminal (8);
=black= wire from switch terminal (4); battery and coil cable
=green= wire from coil front terminal; horn and headlight
cable =green= wire from horn.
11. SPEEDOMETER LIGHT—=Black= wire from switch terminal 2.
12. BATTERY POSITIVE TERMINAL (LEFT SIDE)—=Red= wire with
=black= tracer from junction terminal 18.
13. BATTERY NEGATIVE TERMINAL (RIGHT SIDE)—=Black= wire from
ground clamp on frame.
14. “SWITCH” TERMINAL OF GENERATOR—Generator and relay cable
=green= wire from switch terminal 2.
15. “RELAY” TERMINAL OF GENERATOR—=Red= wire with =black
tracer= from relay rear terminal.
16. OIL PRESSURE SIGNAL SWITCH—=Black= wire from signal light
terminal 9.
17. JUNCTION TERMINAL (BAKELITE TERMINAL PLATE ON HORN
MOUNTING)—Horn and headlight cable =red= wire from switch
terminal 2,—=red= wire with =black tracer= from
handlebar toggle switch (31).
18. FRONT JUNCTION TERMINAL (in motorcycle frame, under
saddle)—Coil and battery cable =red= wire from switch
terminal 3; =red= wire with =black tracer= from battery
positive terminal (12).
19. REAR JUNCTION TERMINAL (in motorcycle frame, under
saddle)—Coil and battery cable =black= wire from switch
terminal 6; =red= wire from stop light switch (20).
RA PD 310278B
20. STOP LIGHT SWITCH—=Red= wire from junction terminal 19;
=green= wire from coil terminal.
21. BLACKOUT STOP LIGHT (Top socket in right taillight)—Taillight
cable =yellow= wire from switch terminal 5.
22. BLACKOUT TAILLIGHTS—Taillight cable =green= wire from
switch terminal 1.
23. SERVICE TAIL AND STOP LIGHT (top socket in left taillight—two
wires in one plug)—Taillight cable =black= wire from switch
terminal 2 is for service taillight, and taillight cable =red=
wire from switch terminal 7 is for service stop light.
24. BLACKOUT MARKER LIGHT (ON FRONT MUDGUARD)—=Black= wire
from switch terminal 1.
25. SERVICE HEADLIGHT—=Black= wire with =red tracer=
from handlebar toggle switch (31) to large terminal screw;
=red= wire with =yellow tracer= from handlebar toggle
switch to small terminal screw.
26. IGNITION AND LIGHT SWITCH (TOP VIEW)—Switch “OFF” in
straight‐ahead position.
27. BLACKOUT HEADLIGHT—Blackout headlight is fitted with
independent switch in lamp body.
28. SPARK COIL—Coil and battery cable =green= wire from
terminal 10 to coil front terminal; =green= wire from stop
light switch (20) to coil front terminal; low tension wire (34)
from circuit breaker (33) to coil rear terminal.
29. HORN—Horn and headlight cable =green= wire from terminal
10; =black= wire from horn switch (30).
30. HORN SWITCH—=Black= wire from horn.
31. HANDLEBAR TOGGLE SWITCH—=Black= wire with =red
tracer= from service headlight terminal with large terminal
screw; =red= wire with =yellow tracer= to service
headlight terminal with small terminal screw; =red= wire with
=black tracer= from junction terminal 17.
32. CUT‐OUT RELAY—=Red= wire with =black tracer= from
“=relay=” terminal of generator to relay rear terminal;
generator and relay cable =red= wire from switch terminal 3 to
relay terminal marked “BAT”; generator and relay cable =black=
wire from terminal 8, to relay right front terminal.
33. IGNITION CIRCUIT BREAKER AND TIMER—Low tension wire (34) from
coil rear terminal.
34. CIRCUIT BREAKER‐TO‐COIL LOW TENSION WIRE—See Description 33.
35. JUNCTION TERMINAL ON BAKELITE TERMINAL PLATE—Horn and
headlight cable =black= wire from switch terminal 1; wire from
blackout headlight (27).
All WLA model motorcycles originally equipped with radio interference
suppression‐devices, or to which suppression‐devices have been added,
can be identified by a large letter S stenciled on left and right sides
of instrument panel cover.
=*A= GROUND TERMINALS ON COIL HOUSING.
=*B= FLEXIBLE BRAID CONDUCTOR.
=*C= CONDENSER.
=*D= SHIELDED CIRCUIT BREAKER‐TO‐COIL LOW TENSION WIRE.
=*E= SPARK PLUG SUPPRESSORS.
=*H= CONDENSER.
RA PD 310278C
_Legend for Figure 73—Complete Wiring Diagram_]
[Illustration: RA PD 310247
_Figure 74—Battery Box Open and Filler Plugs Removed for Service_]
=d. Install Battery.= See that rubber mat is in place in bottom of
battery box and install battery in box so that positive post is on left
side of vehicle, and negative post is on right side of vehicle. Connect
wires to battery positive and negative posts. Fit rubber mat on top
of battery. Install cover and securely tighten thumb wing nuts. Lower
saddle and bar assembly. Install swivel pin on right side of vehicle so
that retaining spring fits in groove in end of swivel pin.
114. HEADLIGHTS.
=a. Service Headlight.=
(1) Remove nut which secures light body to bracket, observing that
conical washer bears against cup of bracket for secure light mounting.
Disconnect wires from light body terminals.
(2) Before installing service headlight, connect wires to light body
terminals, noting that black wire with red tracer connects with the
larger terminal screw. Mount light on bracket. Position conical‐shaped
washer and lock washer and install mounting stud nut. Do not tighten
mounting nut.
=b. Adjust Service Headlight.= Adjustment should be made in darkened
area or at night, tactical situation permitting. Vehicle must be
standing on a level surface about 25 feet away from and headed toward a
wall or screen upon which a horizontal line has been drawn at exactly
the same height as service headlight center. Set handle bar toggle
switch in “BRIGHT” position and check light beam for height and
direction. The top of main beam of light should register on wall or
screen even with, but not higher than, the horizontal line mentioned.
Tilt light body in bracket up or down to correctly aim it in relation
to the horizontal line, making sure that light body is not turned
either to right or left. Securely tighten mounting stud nut.
[Illustration: RA PD 310275
_Figure 75—Blackout Headlight Installation_]
=c. Blackout Headlight.= Blackout headlight is mounted on bracket
which attaches to left upper side of front fork. Blackout headlight
operates when ignition and light switch is turned to the second right
position. However, blackout headlight is fitted with an independent
switch in light body to permit turning it off while other blackout
lights are in use. Blackout headlight body is secured to mounting
bracket by means of a conical washer, lock washer, and mounting nut,
providing a swivel mounting to permit light adjustment.
=d. Blackout Marker Light.= The blackout marker light is secured to
front mudguard by means of a hollow mounting stud, with plain washer,
lock washer, and nut. Light wire passes through hollow stud and is
protected by tubing on under side of mudguard. Blackout marker light
wire connects with No. 1 post on ignition and light switch. Lamp is on
with ignition and light switch in second right position.
115. TAILLIGHTS.
=a. Blackout Stop and Taillight.= Blackout stop and taillight is
mounted on right side of taillight bracket. Light is provided with
top unit to provide blackout stop light controlled by brake‐operated
stop light switch. Bottom unit in the blackout stop and taillight is
regularly used as service blackout taillight and is controlled by
ignition and light switch.
[Illustration: RA PD 310272
_Figure 76—Ignition and Light Switch, Front and Back Positions_]
=b. Service Stop and Taillight.= Light is located on left side of
light mounting bracket. Top unit is used for service stop and taillight
(double filament lamp). Taillight filament is controlled by ignition
and light switch; stop lamp filament is controlled by brake‐operated
stop light switch. Stop light does not operate in daytime when ignition
only is turned on. Bottom unit serves as a spare blackout taillight.
In case the regularly used (right‐side) blackout taillamp fails, its
socket plug can be transferred to this taillight socket.
=c. Stop and Taillight Switch.= This switch is operated by brake
pedal and is located on end of rear support rod on right side of
vehicle. Refer to wiring diagram (fig. 73) and paragraph 118 for wiring
connections.
116. IGNITION AND LIGHT SWITCH.
=a.= Earlier models are provided with lock, later models are
non‐locking.
[Illustration:
=8=—GENERATOR SIGNAL LIGHT.
=14=—GENERATOR TERMINAL TO SWITCH.
=15=—GENERATOR TERMINAL TO RELAY.
=26=—IGNITION‐LIGHT SWITCH.
=32=—RELAY.
=35=—TERMINAL STRIP BINDING POST.
=36=—MAGNETIC SWITCH FOR BLACKOUT LIGHT.
=H=—NOISE SUPPRESSION CONDENSER.
RA PD 310279
_Figure 77—Blackout Headlight Magnetic Switch on Later Models_]
=b. Remove.= Disconnect battery ground wire. Remove instrument panel
cover (par. 119). Disconnect all wires from switch. Remove the four
switch mounting screws and spacers. Switch is now free for removal.
=c. Install.= Mount switch on instrument panel base. Install four
screws and spacers. Connect wires (fig. 73). Connect battery negative
ground wire to frame. Turn switch on. Check lights and horn, tactical
situation permitting. Install instrument panel cover (par. 119).
[Illustration: RA PD 310270
_Figure 78—Wiring Cables, Left Side_]
[Illustration: RA PD 310271
_Figure 79—Wiring Cables, Right Side_]
117. HORN.
=a. Description.= Horn is mounted to headlight bracket by means of
four bolts, lock washers, and nuts. One horn terminal is connected with
operating button, and other terminal is connected to No. 4 ignition and
light switch terminal (fig. 73).
=b. Adjust.= Tone adjusting screw is located in rear side of horn. If
horn fails to operate and moving the adjusting screw does not remedy
the trouble, horn must be replaced. NOTE: _Do not change position of
the adjusting screw located in center of diaphragm._
118. WIRING.
=a. Cable System.= Since ignition and lights are controlled by the
ignition and light switch, all wires terminate at the ignition and
light switch. Cables for wire protection are used, making it necessary
to replace cables rather than individual wires. A study of figure 73
will be helpful when removing or installing any of the wiring cables.
Also study figures 78 and 79 and note how cables are arranged on frame,
and how they lead to the switch panel.
=b. Remove and Install Cables.= When it becomes necessary to replace
wiring cables leading to the ignition and light switch, both fuel and
oil tanks must be removed (par. 107) and instrument panel cover removed
(par. 119) for accessibility.