Head Light flickers off - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 17 (permalink) Old 08-05-2013, 02:05 PM Thread Starter
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Head Light flickers off

Hello fellow riders, I was gifted a 1994 Vulcan 750 from a friend recently with a few issues . Iíve resolved all of the issues save one, the headlight flickers then winks out.

When warming up the bike the head light comes on like it should, when I reduce the choke while the bike drops down to a normal idle the light will flicker and then go out. Iíve found by flicking the flasher button the light will come back on, and stay on until the RPM drops back down at a stoplight. I have noticed it happens only at certain RPMs, so I 'm thinking it might be in the GENERATOR area? This is a cat and mouse game for most of my 11 mile ride to work (and ride home).

This was the final straw for giving me the bike he said, hey Iím good with that!

I asked him what he has done to try and solve the problem; he said he replaced the voltage regulator. The problem did not go away after he did though. Then he got a bonus from his work and got a bigger newer bike and did not want to chase the problem anymore. One of the issues was replacing the battery with a new one......so it's not a battery issue.

Thanks for any input you might have, canít wait to solve the issue and get to worry free ridding.
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post #2 of 17 (permalink) Old 08-05-2013, 02:16 PM
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Quote:
Originally Posted by casualbes View Post
Hello fellow riders, I was gifted a 1994 Vulcan 750 from a friend recently with a few issues . I’ve resolved all of the issues save one, the headlight flickers then winks out.

When warming up the bike the head light comes on like it should, when I reduce the choke while the bike drops down to a normal idle the light will flicker and then go out. I’ve found by flicking the flasher button the light will come back on, and stay on until the RPM drops back down at a stoplight. I have noticed it happens only at certain RPMs, so I 'm thinking it might be in the GENERATOR area? This is a cat and mouse game for most of my 11 mile ride to work (and ride home).

This was the final straw for giving me the bike he said, hey I’m good with that!

I asked him what he has done to try and solve the problem; he said he replaced the voltage regulator. The problem did not go away after he did though. Then he got a bonus from his work and got a bigger newer bike and did not want to chase the problem anymore. One of the issues was replacing the battery with a new one......so it's not a battery issue.

Thanks for any input you might have, can’t wait to solve the issue and get to worry free ridding.
My first thought is the Junction Box (JB)...there are small Relay's soldered on the board, is one of them a Headlight Relay ?
....thinking the relay (contacts) might be stuttering.

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!

Last edited by WilliamTech; 08-05-2013 at 02:18 PM.
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post #3 of 17 (permalink) Old 08-05-2013, 02:57 PM
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The Vulcan is designed do the headlight only comes on after the engine starts (or at least fires) I believe the switch for that is in the junction box. It could also be a loose connection almost anywhere. If you absolutely can't find it, wire the light to a fused wire from the battery, and put in another switch. I had to do that on my Goldwing, the stock switch completely fell apart.

I am a motorcyclist, NOT a biker.


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post #4 of 17 (permalink) Old 08-05-2013, 03:19 PM
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My guess is corroded connection, crappy bulb, or the JB

kenny

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post #5 of 17 (permalink) Old 08-05-2013, 03:51 PM
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check your ac voltage from the stator on the yellow lead that goes to the headlight relay, or just check all the stator ac signal voltages at the regulator. if it was a contact or ground issue it would work the opposite when the load is higher one would think.
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post #6 of 17 (permalink) Old 08-05-2013, 05:53 PM
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I thirdly say its a junction box issue. The head Light Relay is not locking up propperly, but I would check to make sure that you are getting voltage to pin 9 of the JB (like said before it should be ac voltage.
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post #7 of 17 (permalink) Old 08-05-2013, 06:08 PM
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I am also thinking Junction Box, but I would first open and inspect the lefts side controls.

If playing with the flasher button temporarily fixes the light, then the relay must already be engaged....or so logic would suggest.

Open up the control housing and clean/inspect the contacts and look for pinched or damaged wires.

If you still think it is a Junction box issue, you can PM me as I have a spare. We can swap Junction boxes and for a small fee and shipping I can just fix yours and keep it as my spare.
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post #8 of 17 (permalink) Old 08-06-2013, 02:39 PM Thread Starter
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Quote:
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I am also thinking Junction Box, but I would first open and inspect the lefts side controls.

If playing with the flasher button temporarily fixes the light, then the relay must already be engaged....or so logic would suggest.

Open up the control housing and clean/inspect the contacts and look for pinched or damaged wires.

If you still think it is a Junction box issue, you can PM me as I have a spare. We can swap Junction boxes and for a small fee and shipping I can just fix yours and keep it as my spare.


I'll not be getting back to it untell the weekend, I'm sure I'll do all of the above! Thanks for the inputs!
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post #9 of 17 (permalink) Old 08-21-2013, 03:01 PM Thread Starter
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No such luck on a simple fix, chased all the conections, removed the head light and used a tester with the same results. Replaced the ground wire from the battery (it looked iffy) still finding It does it when the motor "pops" down in RPMs.

think it will have to go to an expert, money I don't want to spend.
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post #10 of 17 (permalink) Old 08-21-2013, 07:50 PM
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Quote:
Originally Posted by casualbes View Post
No such luck on a simple fix, chased all the conections, removed the head light and used a tester with the same results. Replaced the ground wire from the battery (it looked iffy) still finding It does it when the motor "pops" down in RPMs.

think it will have to go to an expert, money I don't want to spend.
when the light flickers on and off....do you hear a clicking noise from the fuse box (junction box)?
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