Author Topic: No working lights on 85 K100  (Read 5279 times)

Offline r.k.t

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No working lights on 85 K100
« on: March 10, 2016, 06:53:33 PM »
I bought a beat up basket case, and have fixed quite few things on it so far, but I haven't had success diagnosing why I have no headlight, taillight, turn signals, or horn. Parking lights work, and the brake light works. Diagnostics I have performed, not necassarily in this order:
Tried a known good headlight
I jumped the wires for the headlight at the left side switch plug
I jumped the the green and red wires together and the gray and gray/blue (not sure on the colors) at the ignition switch plug
Turned the key on, and ran a wire from the starter lug to the negative post on the battery
Cleaned all grounds
New relay for the load shedding relay
Cleaned kill switch contacts
Placed jumpers to bypass bulb monitoring unit. BMU appears new, and the warning light goes off after I activate the front and rear brake switches.
The only two things I've noticed that may seem out of place are when I press the start button, that's when LSR clicks, it does not activate when I turn the ign switch to on, and the wire colors on the plug for the LSR do not match the pinout on the wiring diagrams I've found.
Red is on pin 87
Green is on pin 30
Black is on pin 85
The 2 green/blue wires are on pin 86
According to the diagrams I've seen, the green and green/blue wires need swapped.
Before I swap the pinout, is there anything else that I appear to have missed? Does the wiring diagram appear to be correct? I'm asking because I don't want to swap the wiring based on bad info and risk destroying an expensive elctrical component. Does anyone have any thoughts, ideas or advice?
  • Okieland
  • 1985 K100, 1993 Klr650

Offline Laitch

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Re: No working lights on 85 K100
« Reply #1 on: March 10, 2016, 08:17:06 PM »
Welcome, r.k.t.
Has the bike ever been run since you've been rehabilitating it?
. . . the wire colors on the plug for the LSR do not match the pinout on the wiring diagrams I've found. . . . Does the wiring diagram appear to be correct?
Without seeing the diagram, who can say if it's correct? Where did you find the wiring diagrams, r.k.t.? Are they labeled? Have they been accurate during your other testing? Did you mark each wire's position on the relay before you detached the relay for replacement, or are you relying on memory?
  • Along the Ridley in Vermont.
  • 1995 K75 89,000 miles

Offline r.k.t

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Re: No working lights on 85 K100
« Reply #2 on: March 10, 2016, 08:54:12 PM »
Thank you for the reply. 1st thing was to get the bike running. It now does. I attached the diagram I used to this post. I have not used the diagram for any other troubleshooting. The bike was already missing the horn relay and load shed relay. The relay can only be installed one way into the plug. I went with my gut a few mintues ago and swapped the two wires around and the problem was partly corrected. It looks like a PO had the wires out of the plug at some point and failed to reinstall them correctly. The headlight and taillight now work. The turn signals aren't working, the flasher only buzzes and the arrow glows dimly.
  • Okieland
  • 1985 K100, 1993 Klr650

Offline Laitch

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Re: No working lights on 85 K100
« Reply #3 on: March 10, 2016, 09:10:06 PM »
That's more like it. Bert is a reliable source for K100 information. On an abandoned bike, all electrical connections need review. You seem to have done a lot. Have you checked and cleaned the instrument panel plug? Did you check the other wire connections of the relay plug? Its assembly was flawed so the rest of it is suspect. Have the terminals of the plug been cleaned or is it new, too?
  • Along the Ridley in Vermont.
  • 1995 K75 89,000 miles

Offline The Mighty Gryphon

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Re: No working lights on 85 K100
« Reply #4 on: March 11, 2016, 09:17:51 AM »
Is this bike a cafe job by any chance?  Cafe artists are notorious for "improving" the wiring of their bikes. 
  • In my garage in Marilla, NY
  • '91K100RS White/Blue
Current:
'91 K100RS16V "Moby Brick Too"

Past:
'94 K75RT "Ilsa, She Wolf of the SS"
'92 K100RS16V "Moby Brick" (RIP, deceased in a vehicular assault)
'94 K75S Special Edition Dakar Yellow "Cheetos"
'89 K100RS Special Edition "Special Ed"

Offline Inge K.

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Re: No working lights on 85 K100
« Reply #5 on: March 11, 2016, 12:56:15 PM »
The bike was already missing the horn relay and load shed relay. The relay can only be installed one way into the plug. I went with my gut a few mintues ago and swapped the two wires around and the problem was partly corrected. It looks like a PO had the wires out of the plug at some point and failed to reinstall them correctly.


When you mounted a new relay for the missing LSR, did you use just a generic ISO mini relay?
Most common pinout is (usually called) layout type A, BMW using type B where  30 and 86 is swapped.
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Offline r.k.t

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Re: No working lights on 85 K100
« Reply #6 on: March 16, 2016, 01:19:08 PM »
Yes I did.  I bought a bosch one at the auto parts store. Looks like I created that problem and didn't know it. Thanks.
  • Okieland
  • 1985 K100, 1993 Klr650

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