Low Beam does not work - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 03-29-2016, 02:49 PM Thread Starter
1986 VN750
 
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Low Beam does not work

One more electrical issue!!

The low beam on my 1986 is intermittent. Does not work most of the time.

What I've done so far-

1- Replaced the bulb
2- Taken apart the headlight switch and cleaned the contacts/ stretched the contact springs
3- Verified that the blue wire is in the front of the connector. Tried moving it to the empty slot in the back and this makes the high beam not work
4- opened and cleaned all the connections in the headlight casing
5- verified stator is good and charging voltage is now sufficient with new Mosfet

The Headlight trouble indicator is almost always on unless I switch the high beam on. The high beam always works but the low beam hardly ever works and usually shuts off when it does.

Any ideas?

Mosfet R/R and relocated
2 wire Mod for the 1986 harness
VN750.com grill cover
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post #2 of 8 (permalink) Old 03-29-2016, 02:52 PM
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Are you running a stock H4 filament bulb? It definitely sounds like your problem is related to the RLU somehow.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #3 of 8 (permalink) Old 03-29-2016, 02:54 PM Thread Starter
1986 VN750
 
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Quote:
Originally Posted by calebj View Post
Are you running a stock H4 filament bulb? It definitely sounds like your problem is related to the RLU somehow.
Yup its the Sylvania 9003 bulb. Does the same exact thing as the one I replaced.

Mosfet R/R and relocated
2 wire Mod for the 1986 harness
VN750.com grill cover
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post #4 of 8 (permalink) Old 03-29-2016, 03:37 PM
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post #5 of 8 (permalink) Old 03-29-2016, 03:53 PM
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Sounds like a loose wire.

If your high beam is solid, you're getting good voltage on the blue/yellow to the dimmer switch from the reserve lighting unit, and a good connection from the headlight to ground. Either the switch is bad or there's a loose wire between the dimmer and the headlight. Check the connections of the Red/Yellow wire at the dimmer and headlight.

It's possible that the reserve lighting unit is going bad, but I don't think it would manifest with this symptom.

1992 US-nonCA * tuxedo mod * r/r relocated

Vulcan slang for newcomers
Service Manual Download
Wiring Diagram + annotations * still undergoing revisions, but still more useful than the generic one. Let me know if you find mistakes or think something additional should be added
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post #6 of 8 (permalink) Old 03-29-2016, 04:53 PM Thread Starter
1986 VN750
 
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Quote:
Originally Posted by Thorn View Post
Sounds like a loose wire.

If your high beam is solid, you're getting good voltage on the blue/yellow to the dimmer switch from the reserve lighting unit, and a good connection from the headlight to ground. Either the switch is bad or there's a loose wire between the dimmer and the headlight. Check the connections of the Red/Yellow wire at the dimmer and headlight.

It's possible that the reserve lighting unit is going bad, but I don't think it would manifest with this symptom.
I'll pour over the wiring soon. I had the switch open the other day and the low beam was going on and off when i wiggled the wires in the switch. I'm imagining that this means the switch has to be replaced. Any idea where i can get one?

Mosfet R/R and relocated
2 wire Mod for the 1986 harness
VN750.com grill cover
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post #7 of 8 (permalink) Old 03-29-2016, 04:55 PM
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HOUSING-ASSY-CONTROL,LH p/n 46091-1514. I'm sure it would be much cheaper on eBay though. Same part from '89 on. I can't promise that it would match our earlier models though. The early design isn't available.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.

Last edited by calebj; 03-29-2016 at 05:00 PM.
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post #8 of 8 (permalink) Old 03-29-2016, 05:09 PM Thread Starter
1986 VN750
 
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Quote:
Originally Posted by calebj View Post
HOUSING-ASSY-CONTROL,LH p/n 46091-1514. I'm sure it would be much cheaper on eBay though. Same part from '89 on. I can't promise that it would match our earlier models though. The early design isn't available.
Thanks. I'll see if I can verify if the switch is bad. Maybe a few well placed jumpers in the switch... I found a ton on ebay. Just want to be sure before I throw parts at it..

Mosfet R/R and relocated
2 wire Mod for the 1986 harness
VN750.com grill cover
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