Headlight failure - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
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post #1 of 10 (permalink) Old 09-22-2010, 12:52 PM Thread Starter
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Headlight failure

symptoms: No headlight - high or low beam. Headlight failure light is not lit. Headlight bulb is new, fuse is good. With engine running voltage at bulb connector is less than 0.1 v. With engine running pulled connector to reserve light device, also no voltage reading greater than 0.1 v. Tried again with connector plugged in, same readings.

Is there any voltmeter test for the reserve light device?
Any ideas on why I am not getting any voltage at the bulb connector?

Sam
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2003 VN750
Purchased 4/27/2010
@ 23813 miles
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post #2 of 10 (permalink) Old 09-22-2010, 03:03 PM
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Most likely your problem is in the fuse junction box. The headlight diode or the relay has gone bad. If you have the downloaded manuel that is going around, you can check page 15-50 for a diagrame of the fuse box. Check the versis for headlight failure and there it will explain how to reposition the blue wire, to get power to the headlight. The trouble is it will come on as soon as you turn the key, this is a temperary fix. You may need a new junction box. The wire is a real PTA to change it's position. Also in the electrical section is how to check out the junction box on page 15-51. Have fun.

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post #3 of 10 (permalink) Old 09-22-2010, 03:36 PM
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Here is a link to Gadjet`s Vulcan pages with the "Hunt Shunt" to get your headlights on in an emergency. The JB on the vn1500 is a little different than the 750, but the procedure should work for us too. He describes using a short 2" piece of wire to jump between the blue headlight wire and the empty space in the connector beside it. This empty space always has power when the ignition switch is on, and will power the headlight. This should help you diagnose whether the problem is in the JB or not.
http://www.gadgetjq.com/hunt_shunt.htm

Hope this helps.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #4 of 10 (permalink) Old 09-22-2010, 09:02 PM
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Easy way to fix in move blue wire in the JB to the empty pin on the JB. (I believe it is Pin 8 in the 6 pin connector to the empty pin on the 10 connector)
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post #5 of 10 (permalink) Old 09-23-2010, 12:07 AM Thread Starter
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Light relay failed voltmeter test

After following the voltmeter test in the VN750 service manual. I got a bad reading on the headlight relay leads. Will order a new junction box. Will post a reply after I get it installed.

Sam
---------
2003 VN750
Purchased 4/27/2010
@ 23813 miles
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post #6 of 10 (permalink) Old 10-05-2010, 05:28 PM Thread Starter
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put a jumper from jb pin 7 to pin 8

Spent hours understanding the wiring diagram for the headlight and voltmeter troubleshooting the Junction Box and the Reserve Lighting Device. Replaced one at a time both the Junction Box and the Reserve Lighting Device - no luck. gave up all the troubleshooting, could never get 12v coming out of pin 8. Installed a jumper from Junction Box pin 7 to pin 8. Now light comes on with ignition key and stays on during starting. I don't have any starting problems. My mechanic had replaced my Regulator/Rectifier with a higher amp version. Electrical is good on this bike.

Thanks for your suggestions. I would have liked to get it to work like it was designed, but at least now I can get back to riding instead of working on the bike.

Sam
---------
2003 VN750
Purchased 4/27/2010
@ 23813 miles
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post #7 of 10 (permalink) Old 10-05-2010, 08:16 PM Thread Starter
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Junction Box & Reserve Lighting Device wiring diagram

I have attached a drawing I made from info available from different manual's diagrams. Maybe useful to someone else.
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Sam
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2003 VN750
Purchased 4/27/2010
@ 23813 miles
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post #8 of 10 (permalink) Old 10-05-2010, 08:36 PM
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Glad to hear that jumping power from one pin to the next got your headlight working.
Can you post a bigger picture of the wiring diagram? I can`t blow it up big enough to read it.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127
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post #9 of 10 (permalink) Old 10-05-2010, 11:04 PM Thread Starter
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higher res diagram

This is higher res. if it still isn't good enough, let me know and I will try saving it as a pdf file.
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Sam
---------
2003 VN750
Purchased 4/27/2010
@ 23813 miles
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post #10 of 10 (permalink) Old 10-06-2010, 09:17 AM
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I physically moved my solid blue wire to the empty slot on the connector over a year ago and bike is still running strong without issues. As long as you have a good battery, you should be good to go.


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2003 Kawasaki VN750 SOLD
2006 Honda VTX1800C
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