JWS1989

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Hey guys, first post. I've searched high and low for answers to this and I've found nothing. I finally had to join a forum. I have a 1981 XS650 Special. I have no headlight, but I do have gauge lights! I eliminated the RLU and jumped the yellow/black and Yellow/blue wires; with headlight unhooked my high beam indicator on tach reacts to flipping the high beam/low beam selector. If I hook the headlight back up, still no headlight and the high beam indicator stays lit regardless of rocker position. If I hook the RLU up then connect headlight the white RLU headlight indicator comes on and it blows the headlight fuse instantly, yet still no headlight. The bike is charging good, if I initially charge battery to 12.5 volts I get 13.8-14 volts at 3000-3500 Revs; at the battery. Also passes slap test, etc. etc. I am at the end of my rope hanging on to my knot, please send help. Thanks!
 
Sounds like either your headlight bulb is bad or the socket connecting to it is wired incorrectly. I would start by testing the headlight bulb. Take the headlight out of the bike and test it, the high and low beams, by connecting it to a battery. Of the 3 tabs on the back, one is power for the high beam, one is power for the low beam, and the third is a common ground. The wires in the plug are usually arranged like so .....

1jO85je.jpg


So, test each beam with test leads off a battery and then check the plug wiring at the headlight plug and the other ends that connect into the harness. That could be the issue right there. You might have the plug connected into the harness wrong. It connects with 3 separate wires and bullet connectors, not a 3 prong plug. Maybe you have one or more of those plugged into the wrong spots.
 
Sounds like either your headlight bulb is bad or the socket connecting to it is wired incorrectly. I would start by testing the headlight bulb. Take the headlight out of the bike and test it, the high and low beams, by connecting it to a battery. Of the 3 tabs on the back, one is power for the high beam, one is power for the low beam, and the third is a common ground. The wires in the plug are usually arranged like so .....

1jO85je.jpg


So, test each beam with test leads off a battery and then check the plug wiring at the headlight plug and the other ends that connect into the harness. That could be the issue right there. You might have the plug connected into the harness wrong. It connects with 3 separate wires and bullet connectors, not a 3 prong plug. Maybe you have one or more of those plugged into the wrong spots.

I tested with a jumper wires directly from the battery, here is where it gets weird. If I put the negative jumper to ground, and the hot jumper to the high or low beam terminal on the bulb, I get nothing. If I put the negative jumper to the low bean terminal and the hot jumper to the high beam terminal (or vice versa) the lamp comes on. If I use a dedicated ground to the plug I still get nothing.
 
I tested with a jumper wires directly from the battery, here is where it gets weird. If I put the negative jumper to ground, and the hot jumper to the high or low beam terminal on the bulb, I get nothing. If I put the negative jumper to the low bean terminal and the hot jumper to the high beam terminal (or vice versa) the lamp comes on. If I use a dedicated ground to the plug I still get nothing.
Your ground's bad. If it broke inside the headlight, you need a new headlight.

IMG_20200321_132353.jpg
 
I did notice the ground terminal from the pigtail appears to have been hot at some point and arced through the plug insulator.
Pull the plug off the headlight and jumper straight to the bulb terminals. If it works like it's supposed to, it's prolly the pigtail. If it still don't work... the bulbs all it could be.
 
Go ahead and share what fixed it?

Oh sorry, I got so excited I forgot to say. The headlight was bad. I'm guessing the RLU had an internal short, and ruined the headlight. Threw the RLU in the weeds, jumped it, plugged new headlight in, and shazam! You guys are great, thanks a lot for the help! I do have one question, my headlight doesn't come on until I start the bike, is that normal?
 
Yep... normal.

The issue returned, I rode the bike about 10 miles, and in that time it has already burnt out another headlight bulb. All the other lights work fine, it's a Sylvania H6024, and this is the second bulbs in two weeks. They exchanged the last one, I dwon't get that lucky again, any suggestions?
 
Give us some pics on how your headlights mounted to the forks.
 
Did you check the pig tail as suggested, went off script and the problem still exists...........RLU was probably ok..............sounds like a short...........do some continuity, (resistance), testing and pull the connections out of the headlight coupling to check for oxidization or broken wires
 
The headlight appears to be mounted as original and properly.
Looks to be no more prone to vibration than any stock mounted headlight.
Nice!
Did you ever have the original headlight mounted in there ? Perhaps an Automotive Sylvania H6024 is just not as good with vibrations?
 
The headlight appears to be mounted as original and properly.
Looks to be no more prone to vibration than any stock mounted headlight.
Nice!
Did you ever have the original headlight mounted in there ? Perhaps an Automotive Sylvania H6024 is just not as good with vibrations?
I found some small burn marks inside the chromed shell on mine and realized the wire insulation was worn from rubbing and vibration and the reason my low beam kept blowing out.
 
Yes, the vibration is tough on the wiring. I found several rubbed bare wires on mine when I got it, some back around the battery box and some inside the headlight.
 
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