Headlight woes

[gazman]

So noticed today no headlight. Simple fix methinks, change the globe. But no globes fine and unfortunately its 130/100w (no relays) terminals are covered in green death and some evidence of heat. no power at terminals ,power at switch. So my question is do I wire in a new mini harness with relays from the switch to new H4 connector, or chase the problem? oh fuses are all fine.

[rbm]

I think you're in for a problem chase.  The excessive wattage bulb might have caused havoc in the handlebar switches.  The heat caused by the current draw of the higher wattage bulb does tend to melt the plastic in the Hi-Lo switch on the left handlebar causing switch failure.  You may have to disassemble and repair/clean the switch.

[enb54]

Have to agree with Robert on this one, although if you're lucky the "green" is severe oxidation and might just clean up. With your high wattage bulb (globe) though, you'd be well advised to wire in some relays to your handlebar switch and a separate fused wire to carry all that current to your headlamp.

Eric...

[gazman]

Thanks Brickers, I,m thinkin now the tank,dash  ect is removed it would be foolish not to install relays,ceramic H4 socket and thicker wire. Question is do I pick up the wires for the relay at the hi/lo switch or before? (headlight on all the time, local law)

[enb54]

If yours are like ours in Canada, the headlight on my 1991 K75 was wired from the factory to be on (low beam) whenever the machine is running. That means when I wired in relays, just used the switch to turn on the relays, wired a separate fused circuit for the headlight power...

I'm not sure about headlight laws in the USA, but I think they are similar...

[gazman]

RBM it seems you've put me on the right track. If I short the terminals on the hi/lo switch (power to either hi or low beam) the headlight works, which says to me the problem is in the switch. I,ve removed it from the bike, but I,m not sure how to dismantle the switch itself. don't want to break it looks like big $$$$ and hard to get in Australia. Help and advice greatly appreciated.

[gazman]

First the good news, figured out remove pin that holds switch toggle in place and it comes apart easily (and available in OZ) now the bad news power pin in said switch has been eroded (probably due to exess current draw) so looks like I,m up for a new one. $330 ouch. :yow

[koapono]

greetings, once you have the problem sorted and repaired I would add relays if you continue to use high-watt lighting.
you can buy the eastern beaver kit: http://www.easternbeaver.com/ which is well made and space saving or make your own. attached photo is from my 94 1100LT, automotive relays and some larger wires to carry current from battery to light.
in the photo with relays, the yellow, white and brown (w/blue jumper) are from the factory switch/harness and provide power to relay coils through the OEM switch. The red wire (pictured) is from 12VDC source (can be battery or switched voltage), through a fuse, the relay(s) and then to headlamp. Headlamp socket/plug (pictured) is also grounded with higher capacity wire.
Lots of info on site on how to do this, pretty straight forward if you're somewhat handy.
The eastern beaver kit is  "plug and play" and quite easy to install. I have one of these on my 85 100RS.
either way, higher wattage lighting will require larger gauge wire to handle the load.
g'luck

[enb54]

Excellent advice from Koapono, also search for "headlight switch" on this site and you'll come up with things like this http://www.motobrick.com/index.php/topic,6299.msg42238.html#msg42238 which assures you that you are not alone, and a fix is do-able in most cases without buying a new assembly. If the contacts can't be cleaned/fixed, then of course you will have to resort to the more expensive replacement method. Once you have your relay system built and installed, you will never ever have to deal with this issue again. Good luck to you down in Oz...

[gazman]

Thanks motoheads, A bit of solder on the contacts and presto refurbished hi/lo switch. Truly thanks again guys HATE buyin new bits when you can fix it yourself. To my mind its a big part of ridin a bike. relays now an no more headlight dramas. Cheers.

[gazman]

While I was playing I noticed 2 factory relays just behind the instrument cluster. anyone tell me what their for?

[rbm]

Does your LT have the electric windshield?  If so, they are probably for this purpose.

[gazman]

Thank you once again

[subforry]

I wouldn't run a 130/100w bulb, that seems like too much heat and I would be worried about damaging the reflector and other parts.  Go for the relays and a 100/80w.