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post #1 of 34 (permalink) Old 03-12-2009, 11:48 AM Thread Starter
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Headlight problems

Ok so yesterday as im leaving for work I start the bike up to let it warm up a little and notice the headlight doesnt come on... i finish putting my gear on and by the time I am done the headlight is on, so im thinking no big deal.

However this morning i start the bike and same thing no headlight except this time i waited and waited and nothing, i drove to work anyways the whole time trying to see if it comes on or play with the "brights" switch. When i turn the brights switch on it does not indicate on my cluster, nor does it turn on. Everything else works fine, brake light, turn signals everything.

As soon as i get to work it turns on and now when i turn the brights on the other light comes on and it is indicated on my cluster...

So is there maybe somthing simple i could check a lose connection or? I just thought it was wierd because even though i turn my brights on the light on my cluster wouldnt come on.
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post #2 of 34 (permalink) Old 03-12-2009, 11:53 AM
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dunno, check your fuses, and where the bulbs plug into the sub harness, maybe even a short in your switch?



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post #3 of 34 (permalink) Old 03-12-2009, 11:54 AM
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Thought maybe its a fuse... but now it sounds like a loose connection. Check all your hook ups, and make sure they are all securely done up. Maybe your bulb is burnt out?!? I really dont have much of a clue other then that.

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post #4 of 34 (permalink) Old 03-12-2009, 12:01 PM Thread Starter
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well the bulbs arnt burnt out because they do both come on but like i said it was delayed, yesterday only a minute but this morning prolly 30...
if it was a fuse then wouldnt it not come on at all? unless its a loose fuse?
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post #5 of 34 (permalink) Old 03-12-2009, 12:11 PM
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yea if the fuse was burnt you would have no light
if the bulb was burnt there would be no light
it's got to be a short in your wiring or a loose connection of either the fuse or the bulbs



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post #6 of 34 (permalink) Old 03-12-2009, 12:13 PM
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the fact that it doesn't show in your cluster when u turn the brights on makes me think a short in your actual switch possibly....

but then why would the low beam not come on also?



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post #7 of 34 (permalink) Old 03-12-2009, 12:17 PM
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Mine use to do this as well but has stopped for the time being. But it seemed to fix it self was wierd and seemed hard to deal with seeing as I like riding with the brights on as well.

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post #8 of 34 (permalink) Old 03-12-2009, 12:20 PM
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100% know its in your kill switch. Tear it apart, and remove the metal cover thats on the bottom side of the switch I believe, and there is a white/blck wire (I THINK) that has a solder tab on there. It just came unsoldered. Check it out, thats most likely the culprit. Happened to alot of us.

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post #9 of 34 (permalink) Old 03-12-2009, 01:47 PM
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Like suggested check the kill switch also check out the
prongs for the black base that holds the bulb itself its
common to have a short in one of the prongs which causes
the problem you got the base is replacable for 5.95



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post #10 of 34 (permalink) Old 03-12-2009, 04:06 PM
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Quote:
Originally Posted by shiftn3rdon1 View Post
100% know its in your kill switch. Tear it apart, and remove the metal cover thats on the bottom side of the switch I believe, and there is a white/blck wire (I THINK) that has a solder tab on there. It just came unsoldered. Check it out, thats most likely the culprit. Happened to alot of us.

I'd go 99%. Could be a burnt bulb but most likely... kill switch.

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How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #11 of 34 (permalink) Old 03-12-2009, 04:10 PM
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just curious, was the bike ever down?

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post #12 of 34 (permalink) Old 03-12-2009, 05:27 PM Thread Starter
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Quote:
Originally Posted by KylerR View Post
the fact that it doesn't show in your cluster when u turn the brights on makes me think a short in your actual switch possibly....

but then why would the low beam not come on also?
Exactly my thoughts... if this is a switch issue like people are saying that has nothing to do with my low beam it is on by default...
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post #13 of 34 (permalink) Old 03-12-2009, 05:29 PM Thread Starter
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not a burnt bulb people

Quote:
Originally Posted by SkinnyJdcope17
I'd go 99%. Could be a burnt bulb but most likely... kill switch. ?
Quote:
Originally Posted by SkinnyJ View Post
well the bulbs arnt burnt out because they do both come on but like i said it was delayed, yesterday only a minute but this morning prolly 30...
if it was a fuse then wouldnt it not come on at all? unless its a loose fuse?
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post #14 of 34 (permalink) Old 03-12-2009, 06:25 PM Thread Starter
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rode it home from work and didnt have a problem, i did wash it this past weekend so perhaps water shorted somthing out?
i checked the prongs/connectors, those wires everything near the headlight assembly looks ok :(
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post #15 of 34 (permalink) Old 03-12-2009, 09:59 PM
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It's the start button/ kill switch. When you push the start button, it turns off the low beam headlight while it is starting the bike. When you let off the starter button... the light comes back on. Also when you hit the kill switch... it turns off the low beam too.

We're not talking about the high beam switch.

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How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #16 of 34 (permalink) Old 03-12-2009, 11:01 PM Thread Starter
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ok that makes sense what your saying but why would that effect the high beam? ie i turn the high beam on it doesnt come on and it is not displayed on my cluster
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post #17 of 34 (permalink) Old 03-13-2009, 12:55 AM
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Sampsonite, I was way off. Your high beam has a relay. Check it out. You can switch it with the fan relay and if that fixes it... then buy a new relay. If it doesn't fix it... well, we'll cross that bridge when we get there.

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How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #18 of 34 (permalink) Old 03-13-2009, 12:58 AM
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Oh, the indicator in the cluster and the high beam light are wired parallel. Meaning even if the bulb was shot... the indicator would still turn on. So I think you wiring problem is the relay or somewhere before the relay.

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How to fix headlights... Dreamzboy's excellent write-up
https://www.600rr.net/vb/showthread.php?t=138034
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post #19 of 34 (permalink) Old 03-13-2009, 10:48 AM Thread Starter
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Ok well rode again to work and not one problem, so for the time being i will keep this thread on the backburner but i do appreciate the advice so far though guys.
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post #20 of 34 (permalink) Old 03-13-2009, 08:09 PM
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Its prolly a lose wire in the killswitch!

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post #21 of 34 (permalink) Old 03-13-2009, 08:16 PM
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Quote:
Originally Posted by shiftn3rdon1 View Post
Its prolly a lose wire in the killswitch!
What he said.^^^^ Seen this before, and yes...it could be water related, but it is the kill switch. If it's not acting up since you "dried" it out, then resume riding, but you know what you need to do to solve it if it happens again.

You can try wetting the kill switch area or smacking it while bike is running to get a feel for the problem if you feel energetic. It might give you an idea how bad it is (water entry OR loose connection).

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post #22 of 34 (permalink) Old 03-14-2009, 11:17 AM Thread Starter
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Ok so if it is a faulty kill switch then why isnt it randomly killing the bike or anything?
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post #23 of 34 (permalink) Old 03-14-2009, 02:04 PM
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Is there a write up on this with pics? I think I might be having the same problem on my 03
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post #24 of 34 (permalink) Old 03-16-2009, 12:31 PM
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The killswitch house holds a few wire connections, one of them being the headlights. They are just soldered onto a little tab in the housing, which can easily become dissconnected. The wire that actually controls the killswitch is seperate.

Quote:
Originally Posted by SkinnyJ View Post
Ok so if it is a faulty kill switch then why isnt it randomly killing the bike or anything?

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post #25 of 34 (permalink) Old 03-16-2009, 06:45 PM
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I was thinkin it was the starter switch too, but you guys beat me to it. Does your starter button spring all the way out when you release it? +1 on taking it apart to make sure it is good. It is a double pole, single throw switch that basically allows current to pass to the headlight at rest, and when you press it in it breaks that circuit and completes the starter circuit. My money is on a problem with the starter switch. Here is a pic of the switch schematic to help you better understand how it works. I put red dots on the two contacts that the switch connects when at rest (headlight circuit) and blue dots on the two contacts that the switch connects when you press it in (starter circuit)


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post #26 of 34 (permalink) Old 03-17-2009, 10:53 AM Thread Starter
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I was thinkin it was the starter switch too, but you guys beat me to it. Does your starter button spring all the way out when you release it? +1 on taking it apart to make sure it is good. It is a double pole, single throw switch that basically allows current to pass to the headlight at rest, and when you press it in it breaks that circuit and completes the starter circuit. My money is on a problem with the starter switch. Here is a pic of the switch schematic to help you better understand how it works. I put red dots on the two contacts that the switch connects when at rest (headlight circuit) and blue dots on the two contacts that the switch connects when you press it in (starter circuit)

Thanks! My start switch does seem to operate fine, comes out all the way and quickly etc. When I have some time i do plan on taking it apart and checking the connections.
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post #27 of 34 (permalink) Old 03-24-2009, 08:54 PM
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I just had this same problem and upon reading this article, it turns out it was the kill switch,
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post #28 of 34 (permalink) Old 03-26-2009, 10:53 AM
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what was your remedy? new switch, or were you able to fix it?

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post #29 of 34 (permalink) Old 03-27-2009, 10:27 PM
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currently, nothing, I just hit the kill on and off and they work now.
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post #30 of 34 (permalink) Old 03-30-2009, 01:14 PM
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currently, nothing, I just hit the kill on and off and they work now.
You should prolly tear it apart and fix it. It is most likely just barley touching the contact. You could be riding at night and hit a bump and walla, no headlights. It is an easy fix.

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