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Headlight wire problems

Started by Tim-gs, June 22, 2024, 03:26:45 PM

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Tim-gs

Alright having a strange issue here. 2006 gs500f converted to naked. A week ago I replaced my horn that wasn't working and almost immediately the button in the left hand controls shorted out (broken wires in the harness from left hand controls to under the frame) so my horn was always going off. I unplugged the horn to stop it and my headlight went out at the same time. I figured it was just a weird problem that would be fixed with replacing left hand control assembly and harness. I did that today and it did not fix the problem. Getting into diag I was checking for where I do and don't have power and found I have no power to the yellow/white wire for running to the low/high beam switch. Found the same condition at the plug under the gas tank. Unplug the harness and it shows 9v on that pin however as soon as I plug in the left hand controls plug to it no more 9v. Confirmed by back probing the under tank side while plugging and unplugging the harness. Anyone able to help? Why only 9v and 2nd why does it lose that as soon as it's plugged in. Also does it with the old left hand controls after I fixed the harness.

Armandorf

#1
Check the other hand switch


 "at the plug under the gas tank"-where?

also 9 v is a bad battery or a short dragging current somewhere.

From where i had redone the hand controls:


Battery-starter relay->fuse->RED wire to ignition.
ORANGE is the ignition switched power: battery fused power (RED) with key in ON position on the orange wire.

If you have a RH SW right hand light switch, will feed from the Orange, and the headlight switch will send  that through a Yellow with white tracer to the LH SW left hand HI/LO beam switch. Then to headlights : Hi Yellow, LO White

If you don't have a RH SW right hand switch the head lights are fixed from the orange , so you can only change high beam to low beam on the LH SW.

Hi lo beam switch connects to HI (yellow wire) or LO(white wire) that goes to H4 connector for headlamp.
B/W black and white wire goes to battery negative and is grounded.

You can run a wire from the ignition orange to headlamp HI/LO to bypass all the switches.

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