headlight re-visited

[barend]

I've gone through the partial burning headlight bit and resoldered the cirquit. I double checked that a couple of weeks ago when I re-did all the contacts in there. The computer module does not show an error!

 

Having said that, I got caught in a downpour and stopped under an overpass, when i crancked the bike back up I had no dashlights or head light. Running lights, accesory lights and tail light all worked. I assumed a blown fuse so I replaced that at my destination. Turned the key to check they were working, got a flash like a blown bulb and nothing. Still had driving lights so I figured I'd run those on the way home.

When it was time to leave I cranked the bike up, no low beam as expected; wondered about high beam and that came on, switched back to low beam and that came on! What gives??

Since then I've had both low and high beam, I've had no lights at all and I've had the dash warning light on with both the low and/or high beam crapping out part ways. A couple of times rocking the switch seems to have "fixed" it but not always.

I've got an oversized fuse in the panel now and the poles seem to be getting pretty warm. Not real keen on pulling the computer again. Seems like a power drain/short somewhere but have no clue where to start or how to find it. Any suggestions would be appreciated.

[timgray]

Ignition switch going bad, High/low beam switch dirty or going bad.

 

I'd start at those first, clean them up with good electrical contact cleaner.

[Venturous Randy]

I wonder if it could be the Reserve Light Unit?

RandyA

[GaryZ]

My 1985 VR headlight/dashlights failed during an afternoon ride and nearly left me in the dark (literally!). I managed to get home running the flashers.

 

Next day I found the wire from the headlight fuse had burned through . . . It was a couple of inches from the fuse panel.

 

A splice repaired the circuit, however, it looks like this was not the first repair.

 

I am thinking the headlight wiring may be too small and I may rewire with heavier gauge stuff.

[Venturous Randy]

I am thinking the headlight wiring may be too small and I may rewire with heavier gauge stuff.

 

I just wish one of you electronic gurus would come up with a good relay system for these 1st gen headlights that would provide full voltage to the lights and not cause problems with the warning light. There has got to be a better way than what we have now. If you look at the path the circuit has to take to get to the headlight, it is a wonder it even works as well as it does.

RandyA

[sgn]

I too have battled the headlight issue on my 83...

 

The connections in the computer can and will stop the headlight, so a really good redo of the soilder joints is just good practice - even if they look okay.

 

My next step was that I would get it all working and then all of the sudden nothing, no headlight, dash lights - nothing.

 

So my next step was to tear into it all again, clean the connectors at the computer to the wiring harness well - a small nail file worked well get both the male and female ends.

 

Then I took a pair of small neddle nose and applied a slight twist to the female (computer) side of the connector, it was enough that the male end was difficult to get connected. Then once I made sure that the connector was in all the way I pulled enough wire harness up to allow a soild wire tie around it and the metal support.

 

Next I worked may way out to the headlight - cleaning and tightning connections.

At the headlight I made sure that the wires to it where clean and very tight, I even replaced one of the terminals because it would not stay tight when connecting.

 

So far it is working and even survived a little over the handle bar mishap.

 

Another thing I did that seemed to help the light output ( at least I THINK it did)

was to remove the glass from the rubber black boot that goes from the headlight to the fairing, get some uphosltery paint and paint it white. I masked off the portion of the rubber boot that is showing from the front (around the outside edge of the glass).

 

This leaves the black edge and makes the inside white, it really does seem to improve the daytime visiblity of the bike from head on and my wife said the light appears brighter when I have fopllowed her at night. I think it also improves the over all "look" of the front end.

 

So get the connections in the computer soild, clean and tighten everything everwhere and then road test it (the last part is the most fun)

 

Steve Neal

 

[GaryZ]

I just wish one of you electronic gurus would come up with a good relay system for these 1st gen headlights that would provide full voltage to the lights and not cause problems with the warning light. There has got to be a better way than what we have now. If you look at the path the circuit has to take to get to the headlight, it is a wonder it even works as well as it does.

RandyA

 

I am not an electronics guru, but, I have an idea;

I am using a 12V relay (Radio Shack) to switch a stereo power amplifier in my van. If the original headlight circuit is used to power the dash lights and energize a relay, the computer would have its signal and the relay could put serious power to the headlight.

[Squeeze]

I am not an electronics guru, but, I have an idea;

I am using a 12V relay (Radio Shack) to switch a stereo power amplifier in my van. If the original headlight circuit is used to power the dash lights and energize a relay, the computer would have its signal and the relay could put serious power to the headlight.

 

Adding two Relays and a serious Power Supply Wire is the easy Part. But you nee to fake the Computer, take the whole Light controlling Circuit out or live with the Warning Light.

[camos]

I am not an electronics guru, but, I have an idea;

I am using a 12V relay (Radio Shack) to switch a stereo power amplifier in my van. If the original headlight circuit is used to power the dash lights and energize a relay, the computer would have its signal and the relay could put serious power to the headlight.

Building on what Gary said, where does the sensor hook up to tell the computer the headlight is on? Could the sensor be hooked up to the power side of the relay?

[Squeeze]

There are Coil inside the Computer through which the Current to the Head Light goes. By doing so the Coils actuate a Reed Contact which tells the Computer there's enough Current going thorugh the Coil, so the Light should be on. Not enough Current, no reed Contact Action. Hooking the Power Side of the Relay to the Computer doesn't help too much, because the Computer would be the weak Link in the Circuit.

[camos]

Oh, so the sensor coil needs to be in series with the headlight to work. The coil and reed switch setup seems like it might be a basic relay, keep in mind I don't know much about my VR yet. If that is the case then wiring the coil to the relay and then to ground should activate the sensor. Is that possible?

[Squeeze]

Since the whole PCB, where the Coils and the Reed Contacts are, is wired for hot Side Operation, i think this would be not a nice Solution. If it would be that easy, you sure would find a Write-Up about the Mod in our Library. There are some Guys who know how to handle a Soldering Iron and Relays.

 

Doable ? Probably, but not for the average Member here

Smart ? No

[GaryZ]

OK, the computer is looking for current to tell it the headlights are "on". How about routing the original headlight power to the driving lights and let them be the "load". Now a relay can be used for low beam and another for high beam.

[Venturous Randy]

OK, the computer is looking for current to tell it the headlights are "on". How about routing the original headlight power to the driving lights and let them be the "load". Now a relay can be used for low beam and another for high beam.

 

That is a thought, but many of us are either running two 35w bulbs or two 55w bulbs and I think that may be worse on the computer.

RandyA

[camos]

Since the whole PCB, where the Coils and the Reed Contacts are, is wired for hot Side Operation, i think this would be not a nice Solution. If it would be that easy, you sure would find a Write-Up about the Mod in our Library. There are some Guys who know how to handle a Soldering Iron and Relays.

I'm sure there are lots of competent guys on here. I'm just asking questions so I can understand better how my new to me Venture operates. I was not thinking of messing with the PCB.

 

If all the current to the light goes through the coil, presumeably coming from the switch, then I was thinking the supply from the switch to the coil could energize a relay with 87 going to the light and 87a going to the coil with the original supply line from the coil to the light going to ground.

 

Perhaps that won't work but from the description you gave it is a possibility worth exploring.

[camos]

Hmm, just remembered 87a is normally closed wihen the relay powers up 87. In any event running a lead to the coil from 87 would do as intended.

 

Is this topic not of much interest or is everyone who knows something about the way the computer monitor works out touring?

[Venturous Randy]

Is this topic not of much interest or is everyone who knows something about the way the computer monitor works out touring?

 

Actually, I think a lot of us would really appreciate a better working knowledge of the CMS and reed switches and other stuff. Like me, I can usually find poor soldier joints and fix them, but to do anything to fool the system to be able to bypass something is not in my routine.

RandyA

[camos]

I understand your point, this bike is the first one I have had to deal with the complexities of a computer and all the other gadjets and comcomitant wiring. It's kinda overwhelming. I'm in the process of inspecting all the wiring and cleaning connections. Haven't gotten to the computer and don't have any known issues so did not want to pull it although probably should to make sure the harness sockets are clean.

 

This headlight issue caught my attention and it seems to be more complicated than necessary and thought a few questions now might be useful in the future if, or is it when, something related comes up.

 

Thanks for the reply, guess I'll just hang on, keep cleaning and perhaps have a look at it when working in the area.