Headlight not working

OK this is getting odd... I know that everyone on here must be sick of all the charging system questions. But here I go....

I replaced the battery. I am going to order new brushes today. I opened up my altinator cover and looked at the brushes. They look fine but I didn't measure them. I cleand the rotor with a pencil eraser and put it back together. I am still only getting 11.8 volts at the battery @2000rpm. So I will replace the brushes.

However, can anyone tell me why my headlight wont get power? The bike runs fine and I have tail light and turn signals. I check the voltage at the headlight connector and get no power on any of the 3 blades. I check at the fuses (no, I haven't upgraded them yet) and I am getting 11.8 on both sides. I also took apart the left control and I have no voltage at the highbeam switch (3 connectors) To clearify... the headlight does not come on at all. Am I missing a relay or something in the system? I have had a lot of minor electrical issues with the bike Lately. The starter button work's when it wants to, etc...

 

What is the static voltage measurement of your battery? What does it measure after startup? I'll put dollars to doughnuts your seeing battery voltage once you get the system running.
Did you pull the brushes out? You need to lay eyes on their entirety to determine if there are any cracks or broken wires.
I would think your problem is the voltage regulator/rectifier assembly if your brushes are mechanically sound.
As for the headlight, get that fuse block changed pronto! I had a "good" fuse block too. Everything was functioning correctly and it still would cut the headlight off, usually miles from home with rapidly approaching darkness.

 

Statc voltage is 11.8 .. Yes I am only seeing the bttery voltage. I didn't figure on yanking out the bruses until I had a new set on hand.

Still not sure of the headlight issue. I just bypassed the fuse block and I still do not get headlight.

 

Ok,
At least we know for sure that the fuse block isn't your issue. Let's look at what else is in the circuit. The voltage to the headlight passes from the left switch cluster on a Green wire for low beam, a Yellow wire for the high beam. The Black wire is your ground return. The switch switches 12 V from the Blue/Black wire which is routed from your main power relay. This wire also supplies the 12 V to your instrument cluster meter lights. If you don't have meter lights, you are obviously not getting the voltage out of the relay. The relay is fed directly out of the fuse block by the Red (main) and Red/Yellow (headlight) wires (fuses). Have a look at those connections and your switch cluster.
Another question surfaces. Do you have a book on your bike yet?

 

It looks like you have a regulator problem I'd say as well.

You need to start at the headlight checking all of the connections while you have it running and the connector(s) disconnected and check for voltage. Work back to the relay and switch. A wiring diagram helps alot for following wires. If you don't have voltage, work from the fuse block forward checking voltage at connectors.

 

ordered a book last week (not here yet) no wiring diagram yet. (tried to order the XJCD but have not received back any response)

Thanks for the help... I will begin walking the wires to find out whats up.

Funny you metioned meter lights. I have meter lights, the Neutral shines bright, turn signal meter light is bright. But I have no highbeam when I move the switch to high.

 

If your meter lights work, you are getting the voltage past the relay. This suggests that your switch or related wiring is your problem. Hope the problem is easily seen.

 

Check under the seat. Towards the rear of the air filter housing is a connector. Maybe it came unpluged or something. The only reason I say that is because mine just fried and now I have the same symptoms as you. All the lights work and the bike runs but no headlight. Just thought I'd throw that out there.

 

XYXJ650... I have HEADLIGHT again!!!

You hit it right on the nose. Thanks Bro!

Ya know, this is what this site is all about.

Thanks to all of you!

 

glad my misfortune was good for somebody . Although I found the new 3 prong connector for $3. So I should have mine fixed soon! Glad I could finally help someone!

 

That connector (with 3 white wires) is the alternator output. It trips the headlight relay.

I bet your charging voltage is back too........

 

MiCarl you were spot on! I am now charging and have headlight. I did notice though in re-reading this post that you guys were all refering to the 3 prong white wires connection. The one I replaced was the 2 prong Brown and red (or green, I'm at work and can't double check) right next to the 3 prong white wire connection.

Again I want to thank everyone for their help on this!

Now to finish troubleshooting the starting circuit after paying attention to Uncle Sam tonight...

 

Yeah team! Glad your on-line Dennis.

 

Those wires energize the alternator rotor. If they aren't hooked up there is nothing on the white wires. Same net effect.