Headlight help - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 17 (permalink) Old 05-03-2012, 10:42 PM Thread Starter
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Headlight help

Hey everybody,
I have a 94 vulcan 750 and I am wanting to sell...but the head light is not working. I have checked all the obvious things like fuses and bulb. I even bought a new reserve lighting device that goes under the seat. All to no avail. I thought maybe someone might have an idea of what it might be or have heard of a similar problem with this bike. Trying not to have to drop too much more money into it by going to a shop. Any ideas?

Thanks,
Alex


Colorado Springs, Colorado
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post #2 of 17 (permalink) Old 05-03-2012, 11:32 PM
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Have you checked the h-light switch connections or the ignition switch connections? I know my h-light does not come on until I start cranking the engine over.

Good luck.

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post #3 of 17 (permalink) Old 05-04-2012, 03:30 PM
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Try bypassing the switch and wire it to a 12v source to test the other wires and such. Very honestly, could be as simple as a proper ground. WAYYYY too many grounds here and there on these bikes.



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post #4 of 17 (permalink) Old 05-04-2012, 03:40 PM
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Check the charging system. Start the bike, let it warm up a few minuites. Then check the voltage at the battery and bring up the RPMS 3000-4000. Should have a little over 14 VDC. One of the stator leads also operates the headlight relay. Thats how the headlight only comes on when u start the bike.
If the stator is bad the head light wont operate. However if you can ride the bike a long time and the bike dont quit due to a dead batt then I would say its not a charging system issue.
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post #5 of 17 (permalink) Old 05-04-2012, 05:25 PM
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Quote:
Originally Posted by ifixf18s View Post
Check the charging system. Start the bike, let it warm up a few minuites. Then check the voltage at the battery and bring up the RPMS 3000-4000. Should have a little over 14 VDC. One of the stator leads also operates the headlight relay. Thats how the headlight only comes on when u start the bike.
If the stator is bad the head light wont operate. However if you can ride the bike a long time and the bike dont quit due to a dead batt then I would say its not a charging system issue.
Off topic so .....I don't want the forum police after me but. I have to ask does your User name mean" Tractor- trailer Mechanic/tech"?

Oh Yeah,he's right^, there you go right back on topic




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post #6 of 17 (permalink) Old 05-04-2012, 06:09 PM
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post #7 of 17 (permalink) Old 05-04-2012, 09:15 PM
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come on guys.. this ones simple.. the Headlight Relay located inside the Junction Box is acting up...

... If the headlight relay is the culprit, there is an easy (and free)
repair you can do to bypass the relay. This will make the headlight
come on when you turn on the key, instead of when the engine starts.
There are 2 plugs going into your junction box (where the fuses are);
one is a 10 pin connector, the other is an 8 pin connector. Unplug
the 8 pin connector. There are only 7 wires going to this plug, so
one of the holes is empty. Move the blue wire to that empty hole and
plug it back in to the junction box. Now when you turn the key on the
headlight comes on. Let us know if you have any problems.
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post #8 of 17 (permalink) Old 05-05-2012, 11:10 AM
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Most likely Slim is correct and has a good way to get your headlight working again. Just something to think about though most relays need two things to work. A control voltage, in this case that comes from the Stator and a ground. If your missing either of these the relay will not operate and the headlight will not work.
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post #9 of 17 (permalink) Old 05-05-2012, 02:35 PM
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Quote:
Originally Posted by ifixf18s View Post
Not tractor Trailers, Fighter jets F/A-18
That's awesome! My favorite modern fighter!

Back to the issue, it could be a bad relay in the junction box. I had it go out on mine, with some help we managed to force open the box and replace the relay. Works fine now. You can either try doing that, or I have a spare junction box I could send you to test if that's even the issue. Or you can do Slim's bypass.

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Last edited by DaveT319; 05-05-2012 at 02:37 PM.
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post #10 of 17 (permalink) Old 05-05-2012, 02:56 PM
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Quote:
Originally Posted by ifixf18s View Post
Most likely Slim is correct and has a good way to get your headlight working again. Just something to think about though most relays need two things to work. A control voltage, in this case that comes from the Stator and a ground. If your missing either of these the relay will not operate and the headlight will not work.
one other thing they need on the vn750 to work is a good Circuit board on the JB... I used to rebuild the junction boxes for members here... most of the JB problems were due to this same headlight issue... and every single JB I tore down had severe corrosion or burnt circuits on the PCB.
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