Help headlight issue

[Nanna10r]

Sulli came & snatched some bits from "Nana's school Project" yesterday. Hope it's sorted mate BTW you looking at a newer nail or what ?.

[Gosling1]

...and have bypassed the relay so I have lights when I turn the ignition on and then start.....

I reckon you have a dud relay - even though the lights keep working when you have taken the extra power wire away, if the problem persists upon start-up, the coil inside the headlight relay is burnt-out......I reckon this is the problem.

The lights will keep working once current is passing through the relay, but the actual coil in the relay is not energising when you start the bike, so the power never gets to the lights...........and they don't work at startup....

Swap the relay over for a known good one - I bet the problem dissapears. If it works, you will be up for a new relay - these are pretty cheap at SuperCheap, AutoPro etc.

Good luck mate.

[Sulli]

ARGH the plot thickens got home yesterday went to fit some school project parts and ........ the bike doesn't start click ...click ....click on the starter relay no movement from the starter motor battery charge is good go and have a beer in disgust

Tonite pulled apart the starter motor full of carbon and very little in the brush department Checked the armature and all good so off to see the local auto lecky tomorrow to replace the brushes
So its gradually eliminating the issues
In a way I'm glad as this issue has been bugging the bike for ages and as the problems become apparent they are easier to identify and fix

[mike-s]

get the armature touched up in a lathe, makes a hell of an improvement too

[Gosling1]

You should pull the starter solenoid apart as well and check it out - the internal contacts may have carboned-up really badly as well ??

I know on the old zeddies, if the starter motor doesn't spin, the solenoid goes click-click, and the battery voltage is good, then the solenoid needs to be pulled apart and cleaned right up with a brass toothbrush and wizards piss.........it works a treat mate !!

[Sulli]

Just an update
retraced the steps checked out all the appendages and took the generator cover off again and found 1 of the soldered connection in the generator had come adrift got to go dse tomorrow to get some spaghetti insulation and then fix and refit.
It sought of makes sense now and I hope it will fix it

[bonester]

Yup one winding of the stator in a GN250 runs the headlight- maybe your bike is the same?

[Sulli]

Yup one winding of the stator in a GN250 runs the headlight- maybe your bike is the same?

YA !!!!!!! Yep that was the problem and 1 of the winding is dedicated to the headlight. Thats why I was getting a good reading on the recharging system as that winding was unaffected and leading me to think that all was ok with the generator.
Although still needed to replace the brushes on the starter motor as this was a separate issue just to muddy the waters. Any way all good now