Headlight off, occasionally on but usually off

[newrider1949]

Hello all, working through the issues on my new ride slowly but surely - next up, the headlight.

First question: does it come on with ign or does bike have to be running?

I read in the forum archive that there was an issue with the ten-pin connector so took off the fairing and had a look; connection/plug seemed dry with no corrosion. One member mentioned hard wiring the black/white wire or bypassing the plug with an additional wire on joining each side of the black/white. Before I tore into the harness I checked for continuity through the plug on the black/white wire and it tested good.

I see that the headlight wiring is red/black, yellow/black and yellow/red.

Rear lights and brake lights work fine.

Not sure what to check next?

TIA for any pointers

all the best

Larry

[triton28]

Upon inserting the key and turning it to ON the headlight will be off until the start button is depressed and then the headlight under normal operating conditions turns on.
The headlight relay is not energized until the starter motor relay is energized.
Dave

[newrider1949]

Thanks Dave, so just to clarify, if I don't start the bike by pulling in the clutch but just press the button w/ign on, the headlight should come on? I've downloaded the wiring diagram .pdf, just wondering physically where the headlight relay is located?

thanks

Larry

[triton28]

Yes the headlight should come on for the condition you described.
There are 4 relays mounted up inside the headlight area behind the cowling and 3 relays are on the LH side below the battery/flasher unit. I just forget here at my desk where the headlight relay is located but follow the wiring colour code to find it. The attached site may help if you need to get to the relays.
https://www.youtube.com/watch?v=g8UWlfJXrUY
Dave

[SgtSlag]

There are additional relays under the faux gas tank. Been a while since I traced the wiring diagram. Don't mean to muddy the waters, just want you to be aware that there are a number of relays on this bike.

When they are dialed in, right and tight, they're fantastic touring bikes. Don't let the Gremlins get you down. These bikes are amazing on a long tour ride. Cheers!

[newrider1949]

Yes the headlight should come on for the condition you described.
There are 4 relays mounted up inside the headlight area behind the cowling and 3 relays are on the LH side below the battery/flasher unit. I just forget here at my desk where the headlight relay is located but follow the wiring colour code to find it. The attached site may help if you need to get to the relays.
https://www.youtube.com/watch?v=g8UWlfJXrUY
Dave

Thanks Dave, will persevere tomorrow!

Larry

[newrider1949]

There are additional relays under the faux gas tank. Been a while since I traced the wiring diagram. Don't mean to muddy the waters, just want you to be aware that there are a number of relays on this bike.

When they are dialed in, right and tight, they're fantastic touring bikes. Don't let the Gremlins get you down. These bikes are amazing on a long tour ride. Cheers!

Thanks for the encouragement! It's just the headlight issue, everything else is perfect (except I need a RH saddle bad lid and to re-upholster the seats ..[new seat material arriving from Bankok in about a week or so])

thanks

Larry

[triton28]

newrider;
If you would do us a favour and post about the replacement seat covers from Thailand when you have had a chance to familiarize yourself with them.. How good is the vinyl? Do they fit properly etc. etc.
I have seen them advertised and if one considers an upholsterer's estimate of 20-25 hours @ $40-$50.00 per hour for driver's seat, backrest and storage pouch; passenger seat, trunk backrest and radio control pouch; and in my case, the optional RH trunk mounted storage pouch which matches the radio control pouch: then it seems to be a very good deal for the money.
TIA
Dave

[newrider1949]

Yes the headlight should come on for the condition you described.
There are 4 relays mounted up inside the headlight area behind the cowling and 3 relays are on the LH side below the battery/flasher unit. I just forget here at my desk where the headlight relay is located but follow the wiring colour code to find it. The attached site may help if you need to get to the relays.
https://www.youtube.com/watch?v=g8UWlfJXrUY
Dave

Well the headlight relay is on the LH side in the group of three and on checking it clicks away just fine when energized. Jumping a positive to the red/blue connector at relay socket puts on the headlight but there's no power coming in to the relay from the fuse box. When I metered the fuse box across the terminals of the H/light fuse I got Zero also no continuity either. There was a very loose 20amp fuse in the headlight slot and the fuse receiver clips had no spring tension left - plus there were some small areas of melted plastic around the slot.
I removed the fuse box and unplugged the harness plugs so I could take the fuse box out. My plan at the moment is to by-pass the headlight fuse slot and connect an outboard inline 15amp fuse to the fuse teminals. We'll see if that fixes the issue. Obviously PO had had some problems and who knows what he'd done trying to fix it. The rest of the harness looks un-tampered with.

Anyhow, will report back tomorrow after I reinstall the fuse box.

Larry

[newrider1949]

Ok so the outboard fuse worked. I had to run a short jumper wire from the brown in the fuse box teed off the b/w as I'd snipped both the red/blue and white/black off the board. To remove the fusebox to do the work, I had to get the 10 pin connector out and past the tight gap in the frame so had to unbolt frame and coax with a prybar to make enough room. All good now, reassembled and headlight working properly on 15 amp outboard fuse.

Larry