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Steve, do voltage drop tests on the headlight circuit and that will answer the concern. It is typical for motorcycles to use smaller diameter wire than one would wish which results in excessive voltage drop/line loss. 3/4-2 volts is not unusual.
Your point is well taken in so far as the assertion that one should evaluate whether relays are actually beneficial. Some bike models really benefit while others do no, it depends on the voltage drop which is simple to measure.
It would be most helpful if owners would measure voltage drops and post the headlight high beam and ground circuit voltages with the year and model of their bike. Steve's post reminded me that it would also be useful to post whether or not you have cleaned/checked the harness wiring connections.
If we have a representation of the typical voltage drops for various models, it would be useful for those who do not intend to install relays. If one knows, for example, that 1 volt is the typical voltage drop in the battery to headlight, and theirs is showing more, it is then obvious that a bad connection is present. One could then look for the problem before it becomes worse, perhaps melting a connector.
An example of the headlight voltage question is the Honda ST1100 versus Kawasaki KLR650 comparison. The ST does not benefit from headlight (power side) circuit modifications because of miminal voltage drop. It does very much benefit from a relay to by-pass the ignition circuit to fuse box voltage drop.
The KLR650 benefits greatly from headlight relays. Mine had a headlight which was brighter with engine not running thann stock ones with engine running. Installing headlight relays onto the older KLR650's removes the main load from the ignition switch circuit so a main power relay is not required.
HIH
Norm
Your point is well taken in so far as the assertion that one should evaluate whether relays are actually beneficial. Some bike models really benefit while others do no, it depends on the voltage drop which is simple to measure.
It would be most helpful if owners would measure voltage drops and post the headlight high beam and ground circuit voltages with the year and model of their bike. Steve's post reminded me that it would also be useful to post whether or not you have cleaned/checked the harness wiring connections.
If we have a representation of the typical voltage drops for various models, it would be useful for those who do not intend to install relays. If one knows, for example, that 1 volt is the typical voltage drop in the battery to headlight, and theirs is showing more, it is then obvious that a bad connection is present. One could then look for the problem before it becomes worse, perhaps melting a connector.
An example of the headlight voltage question is the Honda ST1100 versus Kawasaki KLR650 comparison. The ST does not benefit from headlight (power side) circuit modifications because of miminal voltage drop. It does very much benefit from a relay to by-pass the ignition circuit to fuse box voltage drop.
The KLR650 benefits greatly from headlight relays. Mine had a headlight which was brighter with engine not running thann stock ones with engine running. Installing headlight relays onto the older KLR650's removes the main load from the ignition switch circuit so a main power relay is not required.
HIH
Norm
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