Headlight Issues!

[mattchew13]

Dear fellow bike gods,

I recently purchased a 1996 RVF400 fitted with a tyga kit. And I have been having issues with the headlights, I checked the globes and replaced them with new ones (the correct ones) and still am having problems. Before I replaced the globes the low lights would barely come on (very dim), and the high beams worked fine. After replacing the globes, only one of the low beam lights works correctly, and the other doesn't even light up. And Again the high beams work fine. Trying to isolate the problem I switched the wiring around on the globes and the other one lit up (which previously didnt light up), while the one that did light up did not.

Looking around the actual globe sockets it looks like some burning/charring has occurred. While reading up leads me to believe that my left gear switch may be blown/cooked from the over voltage. And I am going to order new headlight wiring from TYGA to be safe.

My questions are,

1. Is it worth going and replacing all the fuses to be safe?
2. Where does one obtain a new/working left gear switch (can't find one)
3. If neither of these issues fixes my headlight problem, what else could it be?

Any help is appreciated (thank you bike gods)

[Neosophist]

The most common problem is using traditional H4 bulbs inplace of the H4R bulbs.

The origianl bulbs are 35 watts low beam (70 watts total)

Normal H4 bulbs are 55 watts so 110 watts total.

This extra 40 watts burns out the light switch, you can use H4 bulbs but you need to install an aftermarket relay to bypass the switch.

Assuming it is the problem, not sure if they are available new anymore (will be expensive) but a 2nd hand one that is in good condition is your best bet.

[speedy231278]

I had to replace one of my headlamp connectors as it was charred, although given how much more neatly I did the rewiring of the alternator outputs recently I might revisit it at some point. Shame you didn't spot the left switchgear that was posted on the for sale section on this forum last week (I missed it too!). Look on eBay, or else if you have deep pockets you can buy a new one, it's an eye-watering £112.86 plus VAT from DSS, so you're looking at over £140 landed on your doorstep!! And you'll be waiting a while as being an up to three week lead time I suspect it means it'll be coming from somewhere deep in a warehouse in Japan....

TBH, the fuse should be fine. They either blow or they don't. Although, I guess you might have one that's somehow managed to corrode, and therefore limit the power that the headlamps can draw. But, that's probably just my overactive imagination!

[magg]

What bulbs do you have fitted, thought tyga headlights only came with 35/35 watt bulbs. You need to trace the wiring from each bulb back to the loom and post your results, noting wire colours. Maybe the wiring is simply stuffed up, tyga bulb wattage should not damage the switchgear.

[mattchew13]

The bulbs are 35/35W I made sure to get the correct ones.

[magg]

I see you are looking for a replacement for the handlebar headlight switch. Your investigation has lead to this?

[magg]

As you have an NC35, do your headlights come ON when you turn ON the ignition? You also might want to try wiggling the engine START button with the ignition switch ON and the RUN switch in the OFF position. You may have bad Start button headlight switch.

[mattchew13]

As you have an NC35, do your headlights come ON when you turn ON the ignition? You also might want to try wiggling the engine START button with the ignition switch ON and the RUN switch in the OFF position. You may have bad Start button headlight switch.

Yes, when I switch on the ignition the headlights come on. The problem is, only one of the headlights lights up. And this is the same when the engine is running! But when i switch them to high beams both lights work! It's just when its on lowbeams that only one of the globes lights up. And the globes are new and correct!

[magg]

The lamp that lights is bright or dull?

[speedy231278]

The connector is either iffy, or one of the wires to it is. I used to have this exact issue. If you fiddle with the connector block, it'll probably light up. Chances are the wire is coming adrift and you need to either fix it, or replace the connector, like I did.