A couple of problems......

[Jasondh]

I am having a couple of problems on my 1989 Venture Royale. The first problem is the headlight. Works like a champ on high beam, but when you switch to low, it is very dim, and the warning light comes on. About 2 months ago, while driving home at night, the headlight stopped working. I assumed a blown fuse. After pulling the top off of the fuse box, I found that the fuse was not blown, but the plastic fuse box had been melted near the fontact points, and the contacts were burnt and broken. The next day, I bought a new fuse panel, and replaced the old glass fuses with ATM blade style fuses. After I rewired the box and installed all the fuses, everything worked perfect. About 2 weeks later, the low beam went very dim. Checked and changed the fuse, but still very dim. High beam is perfect. I am also getting a brake fluid light and I have checked the fluid many times. There is no problem with the fluid level, or the brake system. I have had 2 motorcycle mechanics verify this.

 

Also, the computer leveling system is not working. When the key is switched to Acc. the system appears to try to turn on, and then I see what looks like an error code that says E4 and then the screen fades out and seems to lose power. in the corner it still reads PSI in very small letters. I have checked the power to the unit, and it is good. I unplugged the connector to the back of the unit and plugged it back in, and it still does the same thing. I cleaned the connectors, still no success. Then I held pressure on the back of the connector, and it worked. I was able to adjust the system with both automatic and manual settings. However as soon as I let go of the connector, it would turn back off. Any help with these 2 problems would be great.

 

I have seen many posts about re-soldering cold joints, and I have thought about trying this. However, I was wondering if anybody might know a step by step on how to do this. Also, does anybody have pictures of these joints and what I am looking for. Thanks in advance for everybodys help.

[Venturous Randy]

You are correct on the cold solder joints. Your discription of the headlight problem is classic for the CMS needing resoldered. There is a write up in the tech section I believe on this. This is usually the problem on the leveling system also. Try looking at this: [ame=http://www.venturerider.org/forum/showthread.php?t=33328]Information Display Repair - VentureRider.Org[/ame]

RandyA

[Dano]

Looks like someone will be busy over the holidays........

 

Good luck with the soldering gun!

[Squidley]

You are correct on the cold solder joints. Your discription of the headlight problem is classic for the CMS needing resoldered. There is a write up in the tech section I believe on this. This is usually the problem on the leveling system also. Try looking at this: Information Display Repair - VentureRider.Org

RandyA

 

Also with the headlight, check the bulb for a broken filament on the low beam. I had one do the same thing on an '86 I had and it turned out the bulb was bad.

[bald josh]

on the headlight, squidley may have it, mine did the same, low beam dim high worked fine, new bulb solved the prob

[Condor]

I had the dim or no low beam on the '83, and planned on doing the resolder.... someday?? But since I don't do much riding at night I kept putting it off, and adjusted the high beam down and put the resolder on the back burner. BTW a new bulb didn't help. I didn't really like the finish of the dash as it looked like it had been repainted and the white lettering job wasn't the greatest in the world. So I popped for a very low mile dash assembly off Ebay and R&R'd the whole dash. I now have hi/low beam which I still don't use very much.

 

On the CLASS system E4 code. You may be able to dodge the resolder job. Sounds more like all you have is a dirty or bent plug contact if it works when applying pressure to the plug. You might try cleaning the contacts with CRC 26 electrical contact cleaner, and do a visual on the alignment. If everything looks good and it still doesn't work, you may indeed have a cold solder joint. The controller comes apart easily. Just resolder the power leads from the plug to the board. The E4 should go away.

[bobcat]

I concur with Squidley and BJ...I had the same problem.Everytime I turned on the key I got a different problem..I finally replaced the headlight bulb, that fixed it

[Jasondh]

Thanks to everybody for your replies. I ended up re soldering the joints. The low beam is still dim, however, the leveling system is functioning properly now. I removed the bulb from the headlight, and all appeared to be ok. I am going to go ahead and replace the bulb and see if that helps. The good news is, I now know how to remove everything and resolder the joints. I would still be scratching my head if it were not for the people on this site. I am sure I will be back time and time again for tips and advice, as I have alot of other projects to tackle. Replacing rear brakes, fork seals, adjusting carbs, and much more. Thank you all very much.