no headlight - Kawasaki Versys Forum
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post #1 of 26 (permalink) Old 04-20-2011, 02:49 PM Thread Starter
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no headlight

quick summary

recifier problem caught when headlight relay went.... no headlights
new rectifier fitted, new relay fitted(today).... no headlights
bulbs checked ok
fuses checked ok
relay taken out and tested as per service manual ok(checked old 'bad' relay
which confirmed i was doing it correctly)
bike starts and runs normally all other electrics operating correctly
i'm fixing it myself as 2008 bike out of warranty now

any help appreciated, don't want to pay dealer as it will no doubt cost a fortune.

ps i'm in uk, orig thread on other site
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post #2 of 26 (permalink) Old 04-20-2011, 07:31 PM
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Bummer! Had you been doing anything before the light was discovered? Sometimes it has something to do with the last thing you were working on.
Just guessing, but I would look for a broken wire. Get a cheap multimeter or troubleshooting light. Bring up a wiring schematic and start working your way back. Not sure why that would take out your relay and rectifier though. I would hate to pay someone else to do this.
Sorry if you already thought of this. Hope you get it figured out, and let us know.

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post #3 of 26 (permalink) Old 04-21-2011, 12:58 AM
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Unplug socket at headlight and test for live current. Have the motor running while doing this test.
If you get live current on socket then its just the bulb and if you dont get current on the socket check wiring and fuse.

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post #4 of 26 (permalink) Old 04-21-2011, 07:22 AM
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Here's a stupid question and I mean no offense....Have you tried a fresh Globe???
Many times the Globe can fail in the base and still have a filament that is intact.
So be sure to meter the globe its self. Not just a visual check of the filament. ( I see this all the time at work...But if the base fails the manufacturer considers it to be their fault and replaces free of charge regardless of how many hours are on the lamp).
For those running HID lamps....good luck! (no filament...so when the electrodes in the quartz envelope burn down low enough they just can't arc anymore).
OK...I'll shut up now


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Last edited by stagehand38; 04-21-2011 at 07:26 AM.
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post #5 of 26 (permalink) Old 04-21-2011, 07:28 AM
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Quote:
Originally Posted by stagehand38 View Post
Here's a stupid question and I mean no offense....Have you tried a fresh Globe???
Many times the Globe can fail in the base and still have a filament that is intact.
So be sure to meter the globe its self. Not just a visual check of the filament. ( I see this all the time at work...But if the base fails the manufacturer considers it to be their fault and replaces free of charge regardless of how many hours are on the lamp).
For those running HID lamps....good luck! (no filament...so when the electrodes in the quartz envelope burn down low enough they just can't arc anymore).
OK...I'll shut up now
Sorry Sir, I have a stupid question and no offence meant too: What is a Globe..
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post #6 of 26 (permalink) Old 04-21-2011, 08:45 AM
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Globe = Bulb

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post #7 of 26 (permalink) Old 04-21-2011, 09:32 AM
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thought so...

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post #8 of 26 (permalink) Old 04-21-2011, 09:43 AM
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Quote:
Originally Posted by stagehand38 View Post
...Have you tried a fresh Globe???...
Good thought... Never overlook the obvious
.

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post #9 of 26 (permalink) Old 04-21-2011, 12:51 PM Thread Starter
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fixed....

decide to recheck previous days work
bingo.. rectifier
my fault..... rewired rectifier yesterday but had to use crimp connectors spades and leccy grease before covering with heat shrink and almagmating tape

because i used pieces of heavy duty wire i ended up with a few more inches than i started with. i had checked battery was charging but then neglected to check it again after i had manovered rectifier back into position. a couple of the connectors had come loose
rewire take 2.... checked ok......moved to position checked ok.....bolted up checked ok
everything working again

sorry for causing a few of you head aches
believe me it was nothing compared to mine!!!
just goes to show you not to be complacent when making repairs

thanks for your efforts and thoughts much appreciated
mike
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post #10 of 26 (permalink) Old 04-21-2011, 01:29 PM
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No worrys! Just glad it all worked out ok. And, after all...that's why this forum is here.

PS....thanks Kimel for the nice catch regarding what a globe is
in the world of stagecraft, a bulb is something you screw into a table lamp.
we don't use bulbs in our lighting fixture we use globes....I blame it on 'muscle memory'! he he he


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post #11 of 26 (permalink) Old 04-21-2011, 03:39 PM
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Tech speak Stagehand, I'm guilty myself.

Glad you got it fixed Mike.

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post #12 of 26 (permalink) Old 04-21-2011, 08:33 PM
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glad you got it sorted out. and thanks guys on the Globes & Bulbs......

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post #13 of 26 (permalink) Old 04-22-2011, 09:37 PM
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Quote:
Originally Posted by stagehand38 View Post
Here's a stupid question and I mean no offense....Have you tried a fresh Globe???
Many times the Globe can fail in the base and still have a filament that is intact.
So be sure to meter the globe its self. Not just a visual check of the filament. ( I see this all the time at work...But if the base fails the manufacturer considers it to be their fault and replaces free of charge regardless of how many hours are on the lamp).
For those running HID lamps....good luck! (no filament...so when the electrodes in the quartz envelope burn down low enough they just can't arc anymore).
OK...I'll shut up now
Check the bulb w/ a volt-ohm-ammeter guage, for continuity.

Ed
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post #14 of 26 (permalink) Old 04-30-2011, 06:28 PM Thread Starter
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thought I had it fixed....alas no
relay seemed to be ok but after test run it went again, this time with a fuel pump whine as well as no headlight
rectifier fine
new battery fitted to be sure its not that

I traced a fault to the larger socket of multi-relay under tank, the one i've replaced several times, wiring, something not connecting properly
i think its number 11(not sure) on circuit, yellow/red wire
i'd like to try and fix it myself but there's not much extra wire
is it easy to rewire, a couple of the female pins look as if they've seen better days, probably as a result of the rectifier problems i've had in past
anyone know where the pins can be got in UK?
when replacing them do they feed out through the front or pull out the rear of the socket?
as usual all replies/ideas gratefully received
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post #15 of 26 (permalink) Old 04-30-2011, 08:20 PM
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Light bulb in english... We do call it a "globe" (round glass lampshade/glass case) in french, when we should call it "ampoule electrique" (electric bulb).

A globe is a three-dimensional scale model of Earth (terrestrial globe) or other spheroid celestial body such as a planet, star, or moon. It may also refer to a spherical representation of the celestial sphere, showing the apparent positions of the stars and constellations in the sky (celestial globe). The word "globe" comes from the Latin word globus, meaning round mass or sphere.
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post #16 of 26 (permalink) Old 04-30-2011, 08:32 PM
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post #17 of 26 (permalink) Old 05-01-2011, 10:16 AM Thread Starter
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thanks invader
now if I could only stretch the wires a bit to make it easier to work at
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post #18 of 26 (permalink) Old 05-01-2011, 09:03 PM
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post #19 of 26 (permalink) Old 05-02-2011, 03:08 PM Thread Starter
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fixed ?
i hope so !

looked on maplins site for similar connectors,(thanks for the list invader by the way) thought the computer power connectors looked similar.
I had an old desk top computer lying around, so I cannabalised a couple of connector pins.
after a bit of shaping with a pair of needle pliers, i had female connector which I thought might work. it came with wire already connected.

pulled out yellow/red connector pin, pin did look not quite right, oxidised, dirty
anyway replaced with my newly fashioned pin, soldered two wires together, heat shrink covering
reattached socket to relay, held my breath and started her up. all appears ok
took her out for a 30 min run came back all appears to be operating normally
but i've been here before
take her out for a longer run tomorrow fingers crossed
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post #20 of 26 (permalink) Old 05-03-2011, 08:33 AM Thread Starter
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not fixed

i think there is bad/loose earth somewhere
i believe drop in voltage causes headlight relay to go
battery was charging properly 13.8 at idle yesterday rising with revs

now back from test run 12.2 at idle
fuel pump whine (lack of power?)
no headlight again

there was a buzzing noise around main fuse (side of bike)as i got off bike, like a bad connection
but it disappeared when i stopped and restarted engine ??
relay is obviously symptom of main problem
will try and find earth wire to main fuse

but why does it only happen after a vertain time, ride out yesterday was ok, yet same ride today showed problem

booked into dealer for monday, unless i solve in meantime
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