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Discussion Starter · #1 ·
Hi All,



New guys here.... been reading the forums for a few weeks. I've got an '82 GL500i with 30K. Great running bike with no issues until now. Here's the deal....



When I start the bike, sometimes the headlight comes on - sometimes it doesn't. When it does finally come on, it's usually about 2 minutes after it's been running. Almost like it needs to have current running through it to warm it up. It's the same with the highbeam... However, once it's on, it stays on until I cut the engine and need to start the bike again.



I've tried tapping the light thinking a connection was loose, even a few jolts riding it down the driveway doesn't do it.



Has anybody run into this, or have any ideas?



Thanks in advance,



Don in Washington
 

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You probably just need to clean your starter switch. The pushbutton starter switch also has a circuit to turn off the headlight when the button is pushed. When you let up on the button, current is supposed to flow back thru the headlight.



First try opening up the kill switch clamshell and liberally spraying the inside with electrical contact cleaner. Work the starter button while you are spraying. If you put the bike in gear, the starting motor shouldn't operate during this.



If that doesn't fix things, then you will have to take the switch assembly apart and manually clean up the contacts. Lay a large towel underneath to catch the little spring and ball bearing that may fall out. Nothing too difficult, just take your time and you should be able to figure out how to do it.
 

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Discussion Starter · #3 ·
You probably just need to clean your starter switch. The pushbutton starter switch also has a circuit to turn off the headlight when the button is pushed. When you let up on the button, current is supposed to flow back thru the headlight.



First try opening up the kill switch clamshell and liberally spraying the inside with electrical contact cleaner. Work the starter button while you are spraying. If you put the bike in gear, the starting motor shouldn't operate during this.



If that doesn't fix things, then you will have to take the switch assembly apart and manually clean up the contacts. Lay a large towel underneath to catch the little spring and ball bearing that may fall out. Nothing too difficult, just take your time and you should be able to figure out how to do it.


Awesome! Appreciate the fast feedback! I'll give that a try. Now that the weekend is here, I'll take my time. I know this will sound really foolish, (I'm waiting on my service manual) but how do you remove the headlight out of the fairing? I took the turn indicators out and it looks like a sealed case. All I see is the one adjustment screw on the side...



Thanks for your input...

Don
 

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i have to agree with the dirty switch mine is doing it also but i am just to lazy to clean it but i think i should before it doesnt come on......
 

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To remove the headlight from the fairing, first remove the headlight adjustment knob on the inside of the fairing. It is secured with a set-screw. Then remove the nut from the adjustment shaft. The headlight assembly can then be removed from the front.
 

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Discussion Starter · #6 ·
To remove the headlight from the fairing, first remove the headlight adjustment knob on the inside of the fairing. It is secured with a set-screw. Then remove the nut from the adjustment shaft. The headlight assembly can then be removed from the front.


Man, I feel stupid.... granted it was dark when I was trying to figure it out, but thanks! Appreciate your help.

Don
 

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I used to have an intermittent headlight on my '81 GL500. Cleaning the starter button and the headlight switch is a great idea and ought to be done. That didn't solve my problem however. My issue turned out to be in the white plastic electric connector block that the headlight mini-wire harness plugs into. The contacts in that connector were lazy and corroded. I fixed it by using a little file to shine up and male spade connectors. Then I used pointy needle nose pliers and a little screwdriver to gently squeeze the female spade connectors so they gripped a little bit tighter. Two years later, my headlight still works perfectly.
 

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Discussion Starter · #9 ·
I used to have an intermittent headlight on my '81 GL500. Cleaning the starter button and the headlight switch is a great idea and ought to be done. That didn't solve my problem however. My issue turned out to be in the white plastic electric connector block that the headlight mini-wire harness plugs into. The contacts in that connector were lazy and corroded. I fixed it by using a little file to shine up and male spade connectors. Then I used pointy needle nose pliers and a little screwdriver to gently squeeze the female spade connectors so they gripped a little bit tighter. Two years later, my headlight still works perfectly.




Excellent suggestion.... Thanks.



I did clean the button as recommended and so far so good. I will go one further and clean the connectors too.



Appreciate the help!
 

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Excellent suggestion.... Thanks.



I did clean the button as recommended and so far so good. I will go one further and clean the connectors too.



Appreciate the help!


A little di-elecric grease can help keep corrosion down once you get the electrical contacts clean.
 

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Discussion Starter · #11 ·
Since I've cleaned the contact on the starter button, I haven't had the problem again.... Seems to have taken care of it. Thanks for the tips!
 

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glad all worked out for ya bro
 

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By all means invest in a tube of the silicone grease and when you get time go through the other connectors too - especially the ones from the stator.



I dont know where I got them since it's been so long but you can find a set of tiny wire brushes that exactly fit the female ends of the connectors, probably from Snap-On but there's bound to be other sources and they're an invaluable tool to have around compared to the worthless contact cleaner they sell nowadays.
 
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