head light off and on one day to the next

My headlight works fine one day and not at all the next. High and low and high beam indicator all out at the same time. Fuse is fine, switched with turn signal and works fine. A couple of times I reved it and they came on. No problems while riding going out just from one time to the next. All the other lights work fine and the filament wires look fine. Any ideas where to start before I dtart ripping. Thanks.

 

hello

 

Hello and welcome to XJBikes. Your problem could still be the fuse box or maybe in the handle bar mounted switch. The switch you can carefully disassemble the handle bar switch and clean the contacts inside. It all comes apart. The fuse box there are many threads with pictures and descriptions on how to replace the original, which will give trouble sooner or later.

 

Hey Kiwi you have an answer for everything. I'm glad somebody knows their stuff.

 

I will try that. Someone else I talked to mentioned the high low switch. I wasn't sure what that would do right as I turned on the key the light not working, but he said that is a common problem and that the headlights are pretty tough and probably not the light itself. I will check the fuse box in general again. I was lucky enough to get this from the original owner I worked with. 14,000 miles, good shape, only had to replace fork seals. Bought it for $500. Great first bike.

 

You'll be doing yourself a huge favor if you get rid of the old, stock, Fuse Panel ... and wire-in a Brand New, modern, Fuse Panel that accommodates the new style Plastic plug-in fuses.

The old fuse panel's clips holding-in the fuses become so brittle, with age, that they actually break-off.

Since the Headlight is one of those circuits ... it's a good bet that the Fuse Panel is a big part of your trouble.

With only 14,000 Miles on the bike ... once you get that new Panel in there... you ought to be "Good to GO!"

 

Which bike you got?

On most (all?) of the XJs there is a relay that keeps the headlight from coming on until after the alternator is putting out current.

If the fuse panel doesn't fix the problem have a look at the relay, the connectors and the charging system. Note Rick's signature reminding you to check those alternator brushes.

looks suspiciously like a charging system issue.

Still, do the fuse panel first. You will need to do it anyhow.

 

Bingo, fuse panel, culprit numero uno!

 

Gimme 10-Dollars on Fuse Panel across the board!

 

I'd double down on that.

 

The odds are so good on winning that bet you would only get 25 cents to the dollar from the Bookkeeper!

Evens on the switch!

Relay and alternator, outsiders but still have form and have been known to pip them at the post!

 

Alternator Brushes haven't been the distance yet!

 

Thanks for the advice. I don't have a definitive answer yet. I replace the fuse box first. Did not fix it but like you said it definately needed it. 3 of the fuse clips broke as soon as I touched it. Had same results though. Cleaned up switch, not to dirty but good maintenance anyway. Still no light. I took the head light off and cleaned the terminals, not that dirty and wiggled and pressed together every connection I could get my hands on. The light works now as soon as I start up the bike each time. I then cleaned up the battery, not dirty though.
I still have no headlight with the key turned on and not running, but light comes on as soon as I start the bike. All the other lights work fine with just the key on including tail light. Any ideas would be great.

 

Your headlight is not supposed to turn on until you crank the bike. A little quirk but important to know. It sounds like you found your problem by going through the harness and cleaning/wiggling each contact as you came across it. Your issue is corrosion from the sounds of it. The contacts must be clean for a good connection to be maintained. I'll mention that a Pasche Air Eraser (mini media blaster) is a great investment for cleaning contacts. Small and easily operated, it will clean up corrosion that you can't reach any other way. $70+ USD at their website. A compressor is a must.

 

On my bike (32000 km ~ )18000 mi?


The rotor had a bump in it, I should find it and take a picture... It wore down the inner brush to a stub, the outer brush has still almost stock, or more than ballpark 1/2 an inch. I replaced the rotor (and stator because I didn't understand that the rotor had worn the brushes down... or that they were brushes in the first place).



If you want to read a story, don't read if you don't want to


here's how I figured it out:

The mechanics of it ended up that at high temperatures, the bike wouldn't charge at low RPM. At low temperatures I guess the metal and things cooled I guess??? I'd have it running, it would die... Charge up the battery, turn it on, measure... Charging what's going on? Different battery (I had spares).... Dies after on the highway for 1/2 an hour, coming back to home, get on my home street and it dies out. I had brought a multimeter with me, and put leads within reach. I get it started by pushing it, it charges again... how?

I drive down the street and measure again... OH MY GOD IT DOESN'T CHARGE WHEN HOT. Even if I stopped it for a minute, it would charge again.

Then I did the stupid thing, and replaced the stator.

That didn't fix it, so I asked the mechanic, he tells me that it has brushes. And that's when I figured it out. Also I bought a Haynes book. Also it was REALLY hard to get the rotor off. I really didn't like putting that much pressure on it, even after puting some loosening agents in it. If you can believe, getting the bolt out was the hard part.


I had it propped against a wall in 5th with the brake on... I really didn't like it. But it gave eventually, after 2 or 3 days of spraying stuff on it, and 'banging' on it.


I had advice from said above mechanic, I had found a large (lag?)bolt that fit onto the replacement, we put it into where the bolt would go in the rotor, we had a smaller bolt that we put into the other end of the large bolt. We hacksawed a flat screwdriver tip into it so we could adjust the length of the smaller bolt (in the end of the long one), then screw in the large bolt, hit with hammer, pops right out.

I dunno if there's a story section on the forums... Or if anyone cares, but I thought I'd share.

 

I wasn't sure about the light with key on only, I know a lot of other bikes turn on with just the key. I will check the brushes.
With the story, it's nice to know I am not the only one with unusual fix its. These types of things you can't find in a manual. That's why sites like this are so great. There are a lot of general stories in the general forum area so tell away.