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Lectric Gremelins- No low beam headlights

 
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Lectric Gremelins- No low beam headlights
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cane_prevost



Joined: 23 Mar 2010
Posts: 215
Location: Portland Oregon

Post Lectric Gremelins- No low beam headlights Reply with quote
Well, today I decided to tackle my low beams not working. It went out last night when I was riding home. High beam was fine. Replaced bulb as this can sometimes mean a faulty bulb. No luck. With the new bulb the low beam was working intermittently. Sure sign of a pinched wire or loose connection. Pull the thing apart.

Untitled by caneatcal, on Flickr
3 prong plug with 3 wires going in. One black, one purple, and one brown. Need to find which one is for low beam. Follow the wires back to the switch.

Untitled by caneatcal, on Flickr

Looks like I need to take the thing apart. 3 screws later and dropping small bits all over my garage floor I have it apart. (not sure if I'll be able to get it back together) Looks like there are 3 dots on the white plastic piece that connect to the wires that go back to the headlight.

Untitled by caneatcal, on Flickr
I'm betting the dot with the red wire behind it is the hot wire. I'm thinking if I cross over and connect the dot with the red wire with one of the other dots I'll get the lights on..... Took a small piece of wire and bent it in a U. Placed one end on the bottom dot and tried the left and right dots. Sure enough the high beams come on when I cross over to the brown wire side. Nothing when I go over to the purple wire side.

Purple it is. Must be a break in the wire somewhere.

Next test. Get a piece of wire and connect it to the hot on the white plastic piece. (red wire). Connect the other end right at the back of the bulb where the purple wire goes.

Untitled by caneatcal, on Flickr
Bingo! Low beams come on. Good confirmation. Bad wire. Now I just need to find my saulder gun somewhere in the millions of boxes in my garage from our recent move. I have half a mind to just run a jumper from the red wire in the back of the white plastic thing right to the back of the bulb and bypass the whole thing.... We'll see....

Update:
Decided against solder because I was afraid of melting the plastic... Cut the wire and spliced in a new piece.

Untitled by caneatcal, on Flickr

At the other end.


Untitled by caneatcal, on Flickr

Everything works like a boss now. I'd caution against getting inside the switch box though. There are tiny springs and bearings that make the switches work that aren't sealed. They tend to explode into pieces when you take things apart. I was lucky to find all the pieces and get it back together. Took forever....
Fri Sep 23, 2011 12:38 am View user's profile Send private message
saluki10



Joined: 03 Jun 2008
Posts: 86
Location: Quad Cities, IL

Post Reply with quote
Thanks for the info. I'm having a similar problem and this will definitely help. When shifting, my light likes to go on and off, especially when shifting into 1st. I was thinking a crimped wire or something of the sort. A double thanks for the pictures. My reading skills ain't not so good.

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And you know when I'm down to just my socks what time it is.
Thu Oct 06, 2011 12:48 pm View user's profile Send private message
saluki10



Joined: 03 Jun 2008
Posts: 86
Location: Quad Cities, IL

Post Reply with quote
With the nice weather, finally decided to tackle this. My red wire was the problem. Cut off what I hoped was the problem area and found a broken wire. Spliced in a new piece and now my light is on consistently.

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And you know when I'm down to just my socks what time it is.
Mon Mar 12, 2012 8:31 pm View user's profile Send private message
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