Head Light Problems - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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post #1 of 35 (permalink) Old 02-15-2011, 08:02 PM Thread Starter
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Head Light Problems

Rode the bike for about 45 minutes late today. Cut it off for a moment with the kill switch while talking to a neighbor. He said 'are you testing the battery cause your light is on'. I started the bike just by turning the kill switch on and pressing the starter button. Headlight went off. Bike ran fine. After starting the bike multiple times the light came back on. Now when I turn the switch on there is no headlight but after I start the engine 4 out of 5 times the the light comes on. Has always come on when turning the switch on but now not until it is running. If it is running you can turn it off with the kill switch and the light says on. Feedback please if you have ever had this problem.
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post #2 of 35 (permalink) Old 02-15-2011, 09:16 PM
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the light is supposed to come on only when the bike is running, there is a relay inside the junction box (fuse box) to make sure this happens so you have all the battery power possible for starting. when you use the kill switch only, you haven't broken the relay's circuit to turn off the light.
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post #3 of 35 (permalink) Old 02-15-2011, 09:16 PM
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Headlight shouldn`t come on with ignition switch, until you press the starter button.
Not sure if the stator has to start charging first, or if it will light just by bumping the starter button.

Engine kill switch shouldn`t shut headlight off. So that is working right.
It should stay lit until you turn ignition key off.

edit: slim beat me too it.

Gordon

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

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post #4 of 35 (permalink) Old 02-15-2011, 09:31 PM Thread Starter
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Yeh, I said that wrong. It's my Honda 4 wheeler that comes on when the switch is turn on. Any how, my volt/ohm meter is in my van at work so I can't check the charging tonight. I'm leaning toward a relay problems. It's cheeper
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post #5 of 35 (permalink) Old 02-15-2011, 09:55 PM Thread Starter
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Don't have my meter here at home so I checked it the "redneck" way. Hot wired a spotlight to the battery and it got brighter each of the ten times I started the engine, even the 4 times the headlight didn't come on. Must be charging. Relay time.

But I while check it tomarrow with the meter.
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post #6 of 35 (permalink) Old 02-15-2011, 10:43 PM Thread Starter
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Been looking at diagrams,,,, so there is no relay so to speak. It is called a Headlamp Reserv Lighting Devise.
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post #7 of 35 (permalink) Old 02-16-2011, 12:13 AM
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Quote:
Originally Posted by Chuck A. View Post
Been looking at diagrams,,,, so there is no relay so to speak. It is called a Headlamp Reserv Lighting Devise.
There is a headlight relay in the junction box. See figure 157 on page 340 in the Clymer manual.
EDIT: ONLY CANADIAN AND US bikes have the headlight relay.

Or page 298/2395 here, part number 25:
http://www.tocmanufacturing.com/File...nd%20Parts.pdf

The reserve lighting device is a safety feature that turns on the other headlight element when the one that is burning, breaks, and also the warning light on the dash comes on.

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

Last edited by OlHossCanada; 02-16-2011 at 07:44 PM. Reason: add link
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post #8 of 35 (permalink) Old 02-16-2011, 06:10 AM Thread Starter
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Quote:
Originally Posted by OlHossCanada View Post
There is a headlight relay in the junction box.
The web site I found said there wasn't a relay but what it should have said is there isn't a changeable relay. It may have been for other than USA and Canada models just writen in English. Thanks for the info, just have to test tonight to see if it is charging correctly.
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post #9 of 35 (permalink) Old 02-16-2011, 07:55 PM
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Chuck if you have to get a replacement JB, pull the old one apart and see if you can replace the relay with a generic one. It is already broken so no loss if you break it worse. lol

slimvulcanrider was working on modifying the jb to accept individually replaceable relays. I think he gave up on trying to sell them, but I don`t recall if he got one to work for his own vn or not.

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 #10 of 35 (permalink) Old 02-16-2011, 09:21 PM
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Chuck... there is a headlight relay, it is inside the fuse box... there is now easy or cheap way to replace one bad relay... the RLU is 90% of the time no the problem, but the relay is 99% of the time the problem for the headlight. there is a way to wire in automotive relays, I used to offer a Re manufactured Junction Box that incorporated standard automotive relays. If you have the skills with a soldering iron and JB weld, I can get you a step by step write up on how to mod the Junction Box, and you can replace the diodes at the same to to some that are much better than what came from the factory.
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