head light control module

[MR.G]

The head light control module does not retract the head light anymore. Does anyone know if it's repairable or do I need to shell out big $ for a new one. 1984 Pop up Katana

Thanks

 

[Rijko]

i know nothing about the headlight on this model, can't even find it on a partslist.
Did you work on the front recently, have you checked for loose connections, blown fuse etc ?

How should the control module work, when switching the light on pop up the head lamp unit and light up the lamp and the tail light the same time ? What does still work ?
If the head lamp does not work take out the lightbulb and check it, maybe the mechanism won't function when the bulb does not draw power.

Because i know nothing about this i would say start at the control unit, follow the power on the switch.
Does the control unit get 12v, and does 12v go out towards the headlight when flipping the switch ?
If so, follow the switching wire and see where it leads. Measure for 12v at every connector you find.
Can you see a motor operating the pop up, any electrical connections you can get at to check for
proper 12v and connection to ground ?
I guess you either lose 12v somewhere along the line, find a broken pop up motor, or have a ground issue.

 

[MR.G]

Thanks for the reply. The issue is the control module. It does pop the head light up and all works fine except when you turn it off. All lights go out as they should but the headlight does not retract into kits down position. All you hear is a little click noise the comes from the module

 

[Cipher]

The head light control module does not retract the head light anymore. Does anyone know if it's repairable or do I need to shell out big $ for a new one. 1984 Pop up Katana

Thanks

http://members.suzuki-katana.net/ucp.php?mode=register
these folks have the goods on this

 

[Rijko]

found this : http://www.katanaclub.nl/forum/index.php?topic=339.0
They have a cheap alternative using 2 relais and 2 diodes. Schematic is there.

It describes the control unit is hard to find and expensive, and cannot be serviced.
Does the clicking sound come from a sealed black box that really cannot be opened ?

Since you hear the relais clicking, it may work properly.
I would check if there is a wire that puts out 12v at the same time the relais clicks,
that would be an indication the issue is not in the control unit.
Don't know where you can trace this wire, maybe there's a connector you can pull
or a connection on the motor itself.

Umberto describes the motor unit responsible for headlight movement has 3 contact brushes :
1 central disc, 1x pop-up stop and 1x pop-down stop.

Since yours does pop up, cleaning corrosion/dirt on the pop-down stop may help.

 

[MR.G]

http://members.suzuki-katana.net/ucp.php?mode=register
these folks have the goods on this

Thanks Cipher. I signed up yesterday. Just waiting for my registration confirmation approval from them

 

[MR.G]

Thanks Rijko. The position sensor (part of the motor with the 3 contact points) I have taken it apart and clean. It was in very good condition inside. So I will try your idea and see if I can find something wrong. The control module can be opened easily as there is a removable cap on it but once opened the inside is filled with a yellow liquid seller that feel like was or rubber. Odd thing kis that there is a relay partly expossed. The click sound is coming from that relay. I'll take it apart again and take a pic to post. Thanks for your help

 

[MR.G]

Here is a pic with the cap off the module. You can see the partly exposed relay. I was wondering if there is any way to remove the yellow sealer that is poured into the module. Ie put it in a zip lock bag and boil it to melt the sealant. Just a thought.