Headlight Inop

1980xsRider · Posted: August 13, 2009, 10:17 pm Post subject: Headlight Inop

First off, great site. The amount of knowledge on here and the willingness to offer advice is awesome. Those of us with 30 year old motorcycles gotta stick together. So, here is my issue. I replaced a bulb in the tachometer instrument cluster and my headlight no longer works. I have redone the old glass fuses for the automotive blade type in individual rubberized fuse holders. I have cleaned all of the connections in the headlamp bucket as well as the switches on the handlebars. The bike has 15k miles on it, and I have been advised that perhaps the brushes are simply wearing out. Is it possible that the current draw to an itty bitty bulb in the instrument cluster would create enough draw to where the headlight no longer works? If the brushes are getting worn would not all the other lights not work? It appears as though the headlight and instrument cluster lights are not working. Neutral light works, horn works, and turn signals flash once the bike is warmed up. Any thoughts or suggestions on where to start since it isn't the fuses and the bike runs like a champ.

xsleo · Posted: August 14, 2009, 3:46 am Post subject: Re: Headlight Inop

I would start by checking to see that all the wires going to the dash and headlight are all hooked back up. If you missed a ground wire that would keep the lights from working.

1980xsRider · Posted: August 18, 2009, 4:23 pm Post subject: Re: Headlight Inop

Looks like it is my brushes. Apparently I should be running around 14 volts and I am closer to 13 volts. Not enough to close the headlight relay. It is not the relay as that was already tested. Once I get the brushes in and installed I'll let everyone know if that is what it was. Apparently the brushes were at the halfway wear marks. Bike has just under 15k miles on it, but it had sat for close to 6 years. I have put more miles on it in the last 2 months than in the last 6 years.

nj1639 · Posted: August 18, 2009, 5:57 pm Post subject: Re: Headlight Inop

When I first got mine on the road I had headlight issues. Turned out to be the lamp plug needed a good cleaning along with a grounding issue of the plug.

y rotor was basically shot at the time , kept her running on a trickle charged battery.

pumps · Posted: August 18, 2009, 6:58 pm Post subject: Re: Headlight Inop

You could remove the bulb you installed and see if headlight function returns. If not you will have to investigate further.

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