Electrical question

Morning all,

I have a question about the electrical circuit for the headlights.

Basically, my headlights have started to become intermitted at staying on so i followed the wires down from the switch to the connector (behind the headlight, hidden by the front fairing) and wuickly realised this was the problem. The headlight would go on and off with the slightest movement of the wires imeadiately around this connector.

I pulled the connector apart and cleaned the contacts, they didnt look very dirty anyway. the realised that the problem was with the connection of the wires going in to the connector on one side.

My question is, how do i check what wire has a loose connection, and if i find something would it be a simple soldering job?

I thought i would ask on here before i went pulling out all the individual wires not knowing if they can actually be removed!

I hope this makes sense.

Its a 2000 curvey (see my picture on the left!)

Cheers

after looking into it a bit more, might be an idea to buy a whole headlight loom and just change it over.

Like this one....
http://cgi.ebay.co.uk/ws/eBayISAPI.d...m=390019081807

has anyone done this before? and is it a fairly simple electrical job to do....as in un plug all the connectors and remove old loom, then plug in the new one into the same connectors.

Im not very electrically minded and plugging and un plugging connectors is right up my street!

Cheers

You may be able to feel which wire is loose / broken, if vibration is causing the light to switch on/off then it would suggest the wire is broken probably directly where it is soldered / crimped as this is the weakest point. If you can't feel it then you need to use a multimeter on ohms to check the continuity of each individual wire. Alternatively check the wiring diagram as this should show you the designation of each coloured wire, ie which light is intermittent (dipped/main/full) will be switched by a specific coloured wire. Hth.

Swapping the loom should just be unplug/plug, never done it but shouldn't be rocket science. The only other place the wire may be broken is where it is fixed to the bike and it flexes. Hth.

Originally Posted by Kilted Ginger

Swapping the loom should just be unplug/plug, never done it but shouldn't be rocket science. The only other place the wire may be broken is where it is fixed to the bike and it flexes. Hth.

That what i was thinking, as the headlight is on and off when i turn full lock both ways. And i can see the forks rubbing the loom.

So when i fit the new one, i may use cable ties and triy and route it a bit better than it is now.

Cheers for your help. I hope i am able to do this without removing the front fairing to save time.Maybe someone will come along who can advise!

Thanks for your help!

There may be a spare wire in the loom( there often is) that you could use to replace the damaged one rather than replacing the entire loom.

thats good to know!

well iv got my Bible (Haynes manual) with me at work, and keep looking at the wiring diagrams but need to see the bike at the same time i think!

Think it will be best if i remove the whole loom (rather than the fairing to get at it!) and then sit and work out the wiring diagram a bit better.

Just out of interest, why do they put a spare wire in looms? for breakages like mine?

Thanks

Sometimes, sometimes different models have different wiring requirements and sometimes the same loom is used for different bikes and it's cheaper to make 1 loom with extra wires rather than 2 or 3 looms with the specific amount of wires required. The haynes should show you if there is a spare.

cheers for that.

i think i might take out the loom and inspect it closer. if it doesnt seem like there is anything i can do...i will get another one from a breakers yard / ebay.

Cheers for your help.