Help headlight issue

Sulli · Post by **Sulli** » Wed May 09, 2007 8:14 pm

As some of you know I replaced the generator last week http://www.ksrc-au.com/phpBB2/viewtopic.php?t=15717
All went well put a new battery in and fired the bike up all good Tested the voltage across the battery about 13.7 volts about 12.8volts with the bike not running so I assume the regulator is running correctly.
Went to ponti's for the gp and riding home no headlight
Checked fuse
pulled left handlebar switch apart all good
replaced junction box as that has a couple of relays in it
Symptoms
No light hi or low
no flash or overpass
all other items work correctly
bulb works has been checked

So where does the power come for the headlight circuit ?
battery or generator as this is a separate circuit
Don't have a wiring diagram atm if any one can help with that appreciated

Neka79 · Post by **Neka79** » Wed May 09, 2007 8:33 pm

wot bike is it again??

i once had the headlight on my 99 zx6r turn off... on a country road, at abt 11pm...in the middle of nowhere... when i was doing abt 110...and it was a twisty road...

made for an interesting ride home... dunno wot the problem was, came good again, then i never rode it at night, sold it abt 2 weeks later...

bonester · Post by **bonester** » Wed May 09, 2007 8:34 pm

Do you have a testlight or multimeter? I'd first test the socket for power- first between terminals- earth is on one end BTW. If no power there, I'd check between the terminals on that plug and the earth of the battery- if you get power on the second test but not the first, then you have a crook earth to the headlight.
What model is your bike? Some Hondas for example (my CB400) have a switch on the starter switch that disconnects the headlight when you hit the starter. Could be that too. If your bike has headlights that only come on after you have started, then you have a different system- relays to switch the headlight on.

Sulli · Post by **Sulli** » Wed May 09, 2007 9:00 pm

bike is zx6r 1995 using a multi earth appears to be ok no power across the fuse is the power to the headlight to come on prior to starting the bike ??
or after the generator kicks in ?
relays to switch the headlight on. how ever not sure
As the tail lights and instrument lights are working I think i'm looking at a separate circuit
So where to start the fault finding
The relay has 2 lines in with 12volts but somehow I think it has to have 3 positives

1 for low beam
2 for high beam
3 for overpass switch
flying a bit blind atm without a wiring diagram

bonester · Post by **bonester** » Wed May 09, 2007 9:11 pm

There won't be any power across the fuse. There should be power between one side of the fuse holder and earth though.

Sulli · Post by **Sulli** » Wed May 09, 2007 9:11 pm

Neka79 wrote:wot bike is it again??

i once had the headlight on my 99 zx6r turn off... on a country road, at abt 11pm...in the middle of nowhere... when i was doing abt 110...and it was a twisty road...

made for an interesting ride home... dunno wot the problem was, came good again, then i never rode it at night, sold it abt 2 weeks later...

Mate thats nothing I had to negotiate Ipswich motorway at night ask any queenslander ...

It has cow's, kanga's (ask Phil ) B-doubles wombats and dropbears
and you pass the local loony bin and the state prison

Felix · Post by **Felix** » Wed May 09, 2007 10:06 pm

Sulli wrote: The relay has 2 lines in with 12volts but somehow I think it has to have 3 positives

Relay is a switch that is activated by application of electricity. One 12v in is used to activate the switch, the other is the supply for the thing you want to power (headlight for instance).

So typically you have 4 wires, a 12v in from your switch + an earth for it, and a 12v supply in, and a 12v out that becomes active when the switch is on. The out pin is normally a different colour.

You should be able to feel the relay click as you turn it on/off.

Check for a decent earth (no earth on the switching circuit and nothing will work), and that you have good connections, and check all the non earth wires for Voltage.

You also need to check that the out wire actually works - if it is corroded or broken, no electricity will find it's way to the headlight.

Sulli · Post by **Sulli** » Thu May 10, 2007 8:38 pm

Ya got some good tips there
replaced fuse junction box as that was my first thought when that didn't work
have power to dash lights and the fuse as suggested by bonster well it has made me fix that blown globe in the temp gauge

Will work through it over the weekend and see how i go

mothers day sunday so i suppose sat

have pulled the handle bar switch apart but didn't clean the contacts so might start with that to morrow

Sulli · Post by **Sulli** » Thu May 10, 2007 8:46 pm

Can the regulator still be faulty if it is supplying the recommended charge to the battery

as i think al the power wires run through the reg

Felix · Post by **Felix** » Thu May 10, 2007 10:46 pm

Perhaps...the voltage changes depending on revs - the regulator is there to keep that within tolerances. It is also possible that you get the right voltage out, but the cable is crap and it cant supply the necessary current.

I'd be checking everything from the relay to the wiring at the headlight plug...and check all your switch block connectors are in properly too.

Sulli · Post by **Sulli** » Fri May 11, 2007 10:37 pm

Checked and cleaned switch block ran power wire to lights working ,so the earth should be ok checked earth on main harness from generator 25% loss back to negative side of battery but should be within allowance generator good the relay for the fuel pump worries me as the result is not within the tolerances but the fuel pump is working borrowed a haines manual from yappa everything works except the headlight
None of the wiring diagrams actually match the colours on the bike wiring so starting to get pissed orf

Nanna10r · Post by **Nanna10r** » Fri May 11, 2007 11:45 pm

I'll have a look tomorra for the one on "Me School project" sulli been busy with "the latest Joy recipe here at Nana's"

Zteven · Post by **Zteven** » Wed May 16, 2007 1:33 pm

This may help?
http://www.repairmanualclub.com/

Gosling1 · Post by **Gosling1** » Wed May 16, 2007 5:35 pm

Yeh, how did you go with this issue Sulli, get it sorted yet mate ?

Sulli · Post by **Sulli** » Wed May 16, 2007 6:51 pm

Funny thing that electrickity after hours of using the multi meter and little power tester you know the thing with the light in the screwdriver handle finally found that from the fuse box to the headlight is ok
If i apply power from the +terminal of the battery to the wire coming from the relay to the head lights the lights work even when the power wire is taken away hi lo pass work turn the bike off restart its still no lights
So ATM I have rerouted the headlight wire back to the headlight fuse and have bypassed the relay so I have lights when I turn the ignition on and then start.
This will not last for long as the drain on the battery is huge when starting.
so the wire that is suppose to provide power to the relay is the problem but it comes from a number of points 1 is the starter relay 2 is the regulator and 3 is the fuel pump relay which all appear to be on the same circuit so I could be an expensive to to fault find

Why don't the makers if these wiring diagrams provide voltage reading at each connection point to trouble shoot as this as the current directions are to dissconnect the individual units connect up a battery attach to certain connector and test for either resistance or an open circuit.
So that's where I'm at at present
BTY the wire into the relay when the bike is running is providing 0.2 volts if i boost this the relay comes on and every thing works

When I turn the bike off and restart I'm back to square one

Sunday looks like being tricity 101 study in the garage again

But other than that the bike is good