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Electrical issue No headlight no Turn siginal

  • Thread starter Thread starter Recoush
  • Start date Start date
R

Recoush

Guest
Went for a long ride with my daughter on the way back no Turn signal,
then I noticed No headlight no high or low beam

Horn works
kill switch works
Brake lights work
starter works
starts and stop no running issues
too dark to do a battery voltage test

My 1st guess bad Stator, should i order a a Stator ?
Headed out of town for a while and want to fix this when i get back

Also heard that the headlight /turn signal is another candidate?

I did review the stator pages briefly too dark to do any thing tonight.
may have time Monday afternoon, crossing fingers.
 
got back from York and Now it's raining, guess i start with ordering an R&R.
Maybe build one may have the big diodes and rectifiers in my junk box. Will time being the issue off to ebay :>)
 
How about testing stuff first to pinpoint the problem! You can always buy things later; Hopefully, you noticed all the fuss about series R/R's before you go surfing.
 
Check/clean the light switch first and foremost! It's free and light switches are notorious for causing all sorts of weird light related issues on motorcycles.... At least old motorcycles....
 
maybe trace the wires? maybe check the bulbs? maybe the fuse? i wouldn't start with the stator...
 
Your problem is NOT the stator or the R/R. Not saying that they're not bad but neither would cause the headlight to be out or the turn signals to not light up.
 
Recoush said:
got back from York and Now it's raining, guess i start with ordering an R&R.
Maybe build one may have the big diodes and rectifiers in my junk box. Will time being the issue off to ebay :>)
Click to expand...

Hum, do not know why did not see this a week ago.

QUOTE
guess i start with ordering an R&R.
END QUOTE

NO ! !

You have not described a charging problem. (Stator is part of the charging system). You have descrivbed a problem specific to the headlight circuit.

You need a volt meter or at lease a test probe light to throubleshoot this to find where problem is.

You did not say anything about the fuses. Even if fuse looks good, it (79, glass fuse right?)can be broke inside, so replace it anyway (or swap with an other).
Could be problem with connection inside fuse block.
Again, really need some test instrument (and schematic) to check this out further.

Dave

.
 
Last edited:
had to ride home no Headlight (high or Low)
Rear Brake taillight Works

runs does not die / horn works/ Kill switch works
the headlight switch / turn signal switch same control ( no passing switch)

unfortunate this died the day before i left for York PA and was getting dark and now it is raining again.

Figured the Stator was good so ordered the R&R as a backup

back to work on Tuesday ( Field service for Blood equipment this month 4500 Miles driven add York (1500 miles round trip) 6000 miles Been busy :(

Hope to test the battery and stat etc.. may a trace next weekend should have the R&R Wednesday again back up good to have one in any case Fuses
not had chance yet (no burnt smells any place)
 
Update,
Here is what i found :>)

Headlight fuse 10A Blown and melted the Fuse cover (hole in side of cover now)

Under seat
all Stator wires are melted 2 yellow, red/white, Red
under the Japanese Bullet connectors are total Black
some had melted together

the other 2 to the R&R are OK no Chairing

the bike runs and is charging
power off 12.50 volts
running at idle 13.50 volts

Still no head light or Turn signals, replaced headlight fuse at this point

After lunch will have to separate and reconnect plus
going to test the stator after i remove the burnt connectors
obviously some thing cause it to overload and the burnt connectors and blew the Fuse
 
"....obviously some thing cause it to overload and the burnt connectors and blew the Fuse "

You'd like it to blow fuse(s) before the wires and connectors get fried. I'd suspect a short to ground in fusebox area and/or in the R/R connections. Blowing the headlight fuse should not melt the fusebox cover.
 
I got caught in heavy rain one day and shortly after discovered that water had gotten into the wiring harness, just below where the tank and seat meet. Fried one of the connectors and it took a while to discover where the problem was. It was in the rubber sleeve tucked under the tank. I ended up fixing the connectors with water proof ones and installed a flat piece of rubber tubing in the area between the tank and seat to deflect water from getting into that area. It has been a season and have had no problems since then. Still can't figure how water got into a connector that was buried deep in a rubber sleeve, but heavy winds, heavy rain and electrical current don't mix well.
 
Little more detail :>)
The wires for the most part are fine
Turns out the heat of the connections made the Blackened Looks

Cut off the Black tubing over the connectors
inspected the terminals except for a little bit melted tubing sanded off the male end and reinstalled all 4 plugs and now have turn signals and headlight

Obviously had some very high resistance
The Wire colors involved
To the R&R
RED
White with red stripe

Stator 5 wire version
1 of the 2 yellow
1 of the 2 white w blue stripes

As mentioned my stator has 5 wires
2 yellow
2 white with blue stripe
1 green with white stripe

Oddly enough the green with white stripe had no issue
Not sure where the other duplicate color wires are going?

Going to cut the small end of the new silicone tubing slide over the connections.
As soon as I can access photo bucket will upload the photos

So what does the forum think?
 
looks like Basscliff answered part of my issue thanks Dude
here is an abstract from the R&R

Basscliff: You may have noticed that there are a couple of extra wires (circled in yellow above, white/green and white/red) that I have disconnected, cut back, and taped off out of the way. In the original circuit, Suzuki ran one leg of the stator through the headlight switch.

ME:
oddly enough the battery red and this other wire white /red are part of the problem so Looks like i may need to recheck and cut some wires
 
The other duplicate wires go to the regulator. Each duplicate is Y'd off from a single leg of the stator. If you look at the wiring diagram you will see what I'm referring to.
 
tom203 said:
"....obviously some thing cause it to overload and the burnt connectors and blew the Fuse "

You'd like it to blow fuse(s) before the wires and connectors get fried. I'd suspect a short to ground in fusebox area and/or in the R/R connections. Blowing the headlight fuse should not melt the fusebox cover.
Click to expand...

Everything can be explain by high resistance without needing to assume a short.
 
I'm not sure of the wire colors, but I believe the green/white was one of the wires that took a detour through the light switch to disable one of the stator legs when the headlamp was turned off to keep the old system from overcharging. You want to abandon those two wires. You can run a continuity test between them and it will break continuity when you switch off the headlamp. I seem to remember the other wire was white/red. You want to connect the stator wires directly to the new R/R. Since you have a '79, one of each of the duplicate colored wires will be abandoned or twisted together. They are the same wire, split to go to the old separate rectifier and regulator. I hope you are planning to get a series R/R.
 
After further evaluation,
My Bike has no headlight switch other then Hi/ Low

My headlight / turn signals worked intermittently after the connector fix
Decided to install the R&R ordered before my trip to York PA
The new R&R had 3 yellow, so one to each Yellow, White /blue, White/ Red

The Stator Green with white stripe does not connect to the R&R follows the same wire down

My R&R was located under the left cover with the fuses, the starter relay and a mystery module?
The other 2 same colored wires go to this mystery module?

Mounted the new R&R under the left cover fits vertically later will have to find a better method as I am not certain this will be sufficient to heat sink. The wiring is very confusing as I thought the white / red was the issue turns out part of the R&R

18 photos the original R&R is shown but not the new one.
the left cover (electrical) can be seen in the electrical group
The new R&R is just like the One in the Basscliff photo of the R&R

http://s1275.photobucket.com/user/Recoush/library/RR Wiring Headlight Issues
 
If your bike is a '79, then someone changed the switch out for another model year headlight switch. Wonder what else they changed?
 
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