Help: Headlight and neutral signal on instrument cluster don?t work

[hoofahded@gmail.com]

Hello folks,

I own an ?82 GS400E and this morning when out for a ride I noticed that my headlight - both beams - and the neutral light on the instrument cluster weren?t working. Turn signals ok, the high beam light on the cluster works, the gears light up, just those two things? Not sure if they are both on the same breaker, but checked for loose connections and everything appears to be fine? Was working in the garage before leaving, don?t know what happened or how to troubleshoot. Welcome any help / suggestions? Thanks!

 

[LAB3]

Looking at the wiring diagram I don't see anything off-hand that would suggest the neutral switch and headlight having anything in common, you can download a color copy of the diagram here which is much easier to follow than the one in the service manual http://gsarchive.bwringer.com/

Can't say that I know FOR SURE what's going on but I'd start by checking to see if your headlight isn't burned out, this will have you opening up the headlight where a LOT of wires connect and you can then start checking out if there's any obviously burned out wires. What happens many times is a melt down of a wire that goes from the stator up into the handle bars to a headlight switch that no longer exists with "Always on" headlights. If you find a green with white stripe or red with white stripe wire that looks burned then chances are there's been more melting in the wiring harness. That's a bummer but can be repaired.

For now though, stick to the easiest thing to check, your headlight. If the regulator is original and hasn't been replaced then checking the voltage with the engine running and revved up a bit is a good idea, anything about about 14.4v is cause for concern. System voltage goes WAY high when the regulator goes and excess voltage could very easily start burning out bulbs.

 

[Steve]

I learned a long time ago that, if you are experiencing some strange electrical issues, the cause is proably a bad ground. There are two areas that are common to both headlight beams. One is the supply from the fuse to the beam selector switch on the left handlebar. (Be sure to check the fuse with a meter or test light first.) The second area is the ground from the back of the bulb to a connection in the headlight bucket, then on to the chassis.

The neutral light is powered by a different fuse, but you say that other things on that same fuse (gear indicator lights) are working, so I do not suspect the fuse. It's a simple circuit. Power is provided to one side of the neutral light. The other side of the light has a wire that goes down to the gear selector switch, which is on the left side of the engine, near the front chain sprocket. It is a blue wire that goes under the tank and down the left-rear frame rail. There is usually a bullet connector under the tank, near the coils. If you have had the tank off recently, it's possible that the connector got disturbed. It's also possible that the contacts on the switch need to be cleaned.

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[hoofahded@gmail.com]

Thanks so much gents, going to open the headlight cover and start with the bulb and then take it from there.

Cheers,

Seb

 

[hoofahded@gmail.com]

Hello Steve - would you know where the fuse is located? Lost my Clymer so been on google and youtube trying to find out where it is, but keep striking out.

Thanks again,

Seb

 

[Steve]

Sorry, we did not get a 400 past '78, and it was nowhere near what you have.
I have not even seen one, let alone worked on one.

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[LAB3]

The fuse on my 450 is an in-line type in a holder under the left side cover, there is only one for the entire system.