Headlight electrical problem; help? - 600RR.net
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post #1 of 5 (permalink) Old 08-21-2009, 02:53 AM Thread Starter
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Headlight electrical problem; help?

I hope I haven't screwed this up further, but here goes. My headlights have been intermittently shutting off and on while riding. After some troubleshooting, I found that it was a loose connection in the kill switch housing. As a temp fix I tried to press the connection and glue the wire in place, til I can find some way to solder it. Well the glue wouldn't hold, and made a tiny mess of the area. I pulled the wire away from the connection again and cleaned all the glue off of both the wire end and the connecting pad. While using a blade to shave off the glue, I sheered off the pad end of the wire. Should be no biggie tho right? The wire is exposed now, and I tried to connect the wire to the pad... nothing. Perhaps with me making a connection all those times I blew a fuse? I'm going to check them in the morning.

I'm past the point of aggravation here. Here's the pad and wire that are apart:

Is there any way to bypass this without having to solder it? This one connection is killing my headlights. I would be more detailed but I've been on this for hours now and have got nothing but completely dead headlights.


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post #2 of 5 (permalink) Old 08-21-2009, 03:36 AM
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no your fine as long as you solder it. you can just take the mess off the wire with the solder and then solder it back. But yeah check your fuses also

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post #3 of 5 (permalink) Old 08-21-2009, 10:50 AM Thread Starter
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Thing is, I turn the bike on and make contact with the wire and pad, but nothing happens. I checked the fuses, and all are intact. I'm headed to radio shack now for a solder pen and solder, but I'm fearing the worse. If I'm physically making contact and no lights, something's wrong...


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post #4 of 5 (permalink) Old 08-21-2009, 11:38 AM
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If you glued it... chances are that you're not making contact. Once you heat the solder with the gun... you'll burn off the glue and have a good connection. I'm not thinking you have any other problems other than just soldering the wire.

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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 #5 of 5 (permalink) Old 08-21-2009, 12:28 PM Thread Starter
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Yea, that's all it was. Soldered the wire to the pad, light works fine. Sorta.... see, some of the glue seeped down onto the start switch, and the switch sticks now. So I gotta pull the switch out so it doesn't continuously engage the starter. Also, when the switch is engaged, the headlights are off, so... yea. I'ma try to clean the gunk out best I can. My own damned fault for being impatient. Personally I need to a) stop being impatient and 2) stop over-worrying about tiny problems, lol.


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