Electrical Question - Part Two

[iDemonix]

I'm sorry for starting another thread, I've got a step closer however.

Part One: Bodge jobbed L/H switch gear, lights kept cutting out, external switch - complete fuck up.

Part Two:

I've now removed the old L/H Switchgear and fitted the new. It sits on the bar, clips in to its two connectors and operates the indicators, horn and so on fine. Now this is for those who are familiar with electrics:

The headlights have three wires coming from them; white, green and blue respectively (no idea what each does). The blue wires go through a few little connector blocks, but ultimately join on to an earth, where the top frame bolts on that holds the nose cone solid (screw at the front of the nose cone).

The white + green both run connect to each other like a Y split, joining up to become black. So I HAD 2x white and 2x green (1 of each color from each headlight). Now I have two blacks.

http://i.imgur.com/s32x3.jpg

I've been getting the power for that red cable from HERE;

http://i.imgur.com/nYM4F.jpg

I chose that terminal because when I the lights are off, so is the terminal. When I turn on any lights (position, dipped etc) it gets power. When I touch the other end of the red wire to the black with yellow tape, I get full beam lights and the little full beam dash light comes on. If I touch the red wire to the other black wire, I get dipped lights.

This is why I had a switch on my handlebars, although the bodge job drew power from a wire coming out of the L/H switchgear (a white wire if it's any interest). The switch gave power to either of the black cables, giving me full or dipped.

Here's a shitty diagram I did. The blocks indicate these little blue connectors that just join all the wires. The dash lights that I've put a ring around, I put a ring because I'm insure if that is a dash light, it just leads a wire up right behind the dash lights in to a rubber boot. This diagram could be wrong;

http://i.imgur.com/M12J2.jpg

If someone could tell me anything about this I'd be happy. Should the white + green join up? If so, where should they be drawing power from.

I'm so confused, but I'd love to do this on my own. I've had an offer (kindly) from someone on here to sort it if I bring it round, but there's that many wires going everywhere now it'd take me ages just to get it all back together.

Cheers for any help,

Dan

[porndoguk]

dan do you have a haynes manual? if not im sure theres a wireing diagram floatng around, it had all the correct colours of the cables, and that will help you the best,

as i said before if you get really stuck your welcome to drop buy and ill get it all wired and connected right. its hard to do it without looking and testing

also you old switch gear dont fancy sending it to me do you?

i have a broken high beam flash switch one mine and could do with repairing it. and i need a donor switch.

[iDemonix]

Hey Rick,

I'll drop you a PM about switchgear soon. Basically, I've been playing with the light up screwdriver and the continuity tester. I've kind of figured out what wires are doing what (sort of) with a wiring diagram. I've been using power from a terminal and a bit of wire I had kicking round, sending power through different terminals and seeing what lights up etc (sussed the indicators power route out to memory now lol) but obviously my headlights don't have anywhere to connect and I can't see where they would?

Would you be able to have a glance at the back of your headlights and see where the wires go? I'm no good following this wiring diagram.

It makes me feel better having your offer, that way if I give up I can come to you, but for now I feel like I'm not too far off (and I've spent hours learning what wire is doing what) so I'd love to get this working on my own. I just need to know where the wires from the headlights connect to the bike.

Cheers,
Dan

[porndoguk]

Ill grab my haynes when home and look at the wireing diagram, all my headlight wires run through the main loom and are taped up, but all i can suggest is follow the wiring diagram its easy once you get your head around it.

will be about 6pm ish ok mate

[porndoguk]

here you go dan,



just had a bit of a read of the haynes diagram whilst in the shit house,

your three head light wires,

Green = Earth / Negative
White = Dipped Beam / Positive
Blue = High Beam / Positive

all three work in paralel to the other light, so take your pick on which side to join or connect too.

the then green travel and terminates into the looms crimp, dont ask where but you can crimp or solder it to any other green wire EXCEPT the green and red one (NEUTRAL/CLUTCH WIRE)

ill hazard a guess your bike is a jap import and therfore will not have a dipped beam relay, if so the live for the dipped beam goes into the lhs switch via the black with brown, and then goes out via the white or (white and blue) high beam runs via a relay which is situated down by the clutch case cover.

you need to check the highbeam relay and if theres been a bodged attempt to wire a low/dipped beam relay for the bike, because of the UK H4 bulbs running 55w as oposed to the jap ones running 35W. hope this helps, if i were closer it would have been done and dusted now fella, but as i said the offer stands if you fancy a sat or sun ride over,

Rick

[iDemonix]

Tah very much mate, I'll take the lower fairing off tomorrow and see if the high beam relay has been toyed with (hopefully not!)

What I find odd is that white and green come from one bulb, white and green come from another. If I light up the left bulb to a live (white + green twisted together, then that twist wired to a live) then I get dipped. If I light up the right bulb to a live in the same way, I get high beams.

It is a jap import yes.

What I've been trying to do is use a light up screwdriver in each terminal, then setting the lights to off, side, dipped, high and seeing what changes. I've found one that comes on for sidelights, but none that come on and off when I toggle up to dipped or high.

I'll have another good play tomorrow as I'm off work, if I can't get it done tomorrow I'll drop you a PM and come see you sometime.

Cheers,
Dan

[iDemonix]

Face palm. Took the right hand upper fairing off, saw a massive bunched up piece of electrical tape. Unbunched it, there's four female spade connectors - what the hell? I connect my screwdriver to each one on turn, one of them is my high beam, blue with white stripe - screwdriver lights up when I engage full beams. So if I get some male spade connectors and wire the greens (or was it whites) to the blue + white I'll have working full beams.

So now I just need to find a wire that lights up the screwdriver when I enable dipped. I've got a wire that lights up when I set the lights to side lights, just can't find one that only lights up on dipped.

From what I understand the slider has positions O P H, O = Off, P = Parking/Side H = High. When in the H position, I get dipped if the button is on LO. If the button is HI I get high beams.

Getting somewhere, this is actually quite fun.

[iDemonix]

Upon inspecting the wiring diagram, turns out these spades should clip in to a high beam relay. So I don't have a high beam relay OR a low beam relay. Excellent.

Anyone know the part # so I can ring some local honda dealers or any pattern parts that'd fit, I want to get it fitted today rather than buy a part off eBay or Rick O

Cheers,
Dan

[porndoguk]

all the low beam stuff on jap bikes is on the LHS and goes in and out of the swith back up the loom to the head lights the high beam goes to the lhs, and then back into the loom, over to the RHS relay and then back into the loom upto the head lights, hope that helps a little more,

once you get the colours of the cables into your head it all makes sence,

i guess the old switch was knackerd/burnt out, so the guy wired the other switch in to by pass it for dipped and high beam,

well get your right dan.

[iDemonix]

I've bridged two of the spades (I've rang honda about a relay, they'll ring me back later), the blue and blue + white stripe. Now I have a terminal behind the clocks, that when I apply full beams (H + HI) I get power to that terminal. So if I wire the high beam to that terminal I can have working high beams.

My sidelights work too.

My only problem is, with the aid of my light up screwdriver, I can't find a connection anywhere that will give power then H is on the switch but LO on the button (dipped). The side lights have their own connectors, yet when I enable sidelights, I have a connector in the main terminal block that gets power. I COULD wire my dipped circuit to that, but then I'd never have just sidelights. Only sidelights and dipped, sidelights and dipped, full beams. I can't find a connection for just dipped power. Driving me crazy.

What is it relays do exactly? I've just bridged two spades and it works fine but I'm assuming it'd cause damage in the long run.

Cheers,
Dan