so, maybe its not a big problem after all - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
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post #1 of 11 (permalink) Old 05-19-2008, 12:19 PM Thread Starter
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so, maybe its not a big problem after all

ive been diagnosing my elec problem on my 93 750 for the last few months (i know, i know, but i dont have a lot of free time.)

anyhow, the orig problem stemmed from it sitting outside for a year in the elements. i replaced the starter solenoid.

then when i start her and rev the motor the headlight would dim. ive been testing the charging system. i replaced the R/R (it was under the batt when the batt ran over and corroded it to hell) at about 5000 rpms it dims to the point you cant see it at all. (this is just the headlight, the running lights are fine)

so, still does it. been going through the "electro" flow chart that helps check the charging system problems. first go round i made it right to "charging system ok" because at the batt it reads 13.5 at 2500 rpms and 13.5 at 5000 rpms.

i just noticed that a part (that ive been told is the "lighting module") is cracked. its a small box with 3 prongs connectors on the bottom. maybe measures 1''x1''x1'' and has a slot in the side for mounting to the batt box i think.

before i order a new one, could that have been the problem all along?

Last edited by skaere; 05-19-2008 at 12:21 PM.
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post #2 of 11 (permalink) Old 05-20-2008, 10:30 AM
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does this box have two orange and one black/wellow wire?
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post #3 of 11 (permalink) Old 05-20-2008, 01:08 PM Thread Starter
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i believe so (this is from memory cuz im at work) but i think it does.

ive been told it was also the "reserve lighting module" or something like that.
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post #4 of 11 (permalink) Old 05-20-2008, 05:03 PM
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The one with three wires...2 orange and one black/yellow is your flasher unit...if this wasn't working, your running lights and turn signals wouldn't work. the Reserve Lighting Unit (RLU) is located on the right side of the battery box right under the starter relay. I was having simular problems to you and replaced it...now works great...another problem that i see commonly on here is with the junction box.

Do you have a manual for your bike?
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post #5 of 11 (permalink) Old 05-22-2008, 07:40 AM Thread Starter
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just got a clymers for it a couple days ago.

its the RLU that seems cracked. You think this would cause my headlight to dim when i rev the motor?

kawasaki dealer for one of those or is there a better source?

EDITED:

called the kawi dealer and they want $125 bucks for the reserve lighting module. so before i order it, is there a way to check mine?

Last edited by skaere; 05-22-2008 at 03:14 PM.
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post #6 of 11 (permalink) Old 05-22-2008, 10:23 PM
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is your white headlamp light coming on?
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post #7 of 11 (permalink) Old 05-22-2008, 10:26 PM
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ELECTRICAL SYSTEM 15-37

Headlight Reserve Lighting System Inspection (US and Canadian Models)
If either high or low beam burns out, the reserve lighting system switches over to the remaining filament automatically, and lights the white headlight failure indicator light to show that the headlight bulb must be replaced. If the high beam filament burns out, the low beam is automatically turned on; if low beam burns out, the high beam is turned on but more dimly than normal.
The US and Canadian models contain a relay in the headlight circuit. In these models, the headlight does not go on when the ignition switch is first turned on, but the headlight goes on once the starter button is pushed to start the engine, and stays on until the ignition switch is turned off. But the headlight goes out whenever the starter button is pushed to restart the engine after engine stalling.
*If all wirings and components other than the reserve lighting device check out good, the device is defective.



Turn Signal Circuit
Turn Signal Light Bulb Replacement
•Unscrew the mounting screws to remove the lens.
•Push the bulb in, turn it counterclockwise, and pull it

out.

‘a

•Be sure the socket is clean.
•insert the new bulb by aligning the pins with the grooves in the socket.
•Push the bulb in, turn it clockwise, and release it. It should lock in position.
Be careful not to over tighten the lens mounting screws.

A. Bulb

A. Mounting Screws



Headlight
Dimmer Switch Position Headlight Failure Indicator Light Reserve Lighting

Both high and low beam filaments are normal HI Goes on (hardly visible)

LO Goes on
(hardly visible)

High beam filament burned OUt HI Goes on Low beam comes on.

LO Goes on
(hardly visible)

Low beam filament HI Goes on
burned out (hardly visible)
J

LO Goes on High beam comes on dimly.


go to http://www.tocmanufacturing.com/Products.htm It has more info than the Clymer....I use both constantly.

Last edited by slimvulcanrider; 05-22-2008 at 10:34 PM.
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post #8 of 11 (permalink) Old 05-23-2008, 06:23 AM Thread Starter
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headlamp comes on but dims to the point that you cant see it by 5000 rpms.

im still thinking its a short but i havent found where yet. =/
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post #9 of 11 (permalink) Old 05-23-2008, 10:06 AM
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check the neck...I don't think it is your RLU or your Thermal Flasher Unit....check the ignition switch, and the switches on the handle bars...(both sides)
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post #10 of 11 (permalink) Old 05-23-2008, 05:56 PM Thread Starter
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well damn it. i ran through the elec system tests from electrowhatever.com (the pdf flow chart you can download) and when i ran the voltmeter from the output of the R/R to the batt at idle i had a reading of 0.4V for both (i followed the directions)

aparantly i have a bad connection from both the pos and neg of the battery. i guess im back to unpluging and cleaning every connection again. i hate electrical gremlins.
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