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Discussion Starter · #1 ·
Hey all, I'm having a bit of a problem with my headlight today.



Here's the story...



After work, I headed to my mom's house to pick up my bike, which is where I keep it to take the train to work on nice days. Well, about a half of a mile into my ride, I noticed my reflection in a shiny cargo van. I immediately noticed that the headlight wasn't working. So, I pulled over to try to figure out what the issues was.



I start tinkering with it and figured the bulb is blow, but trying to hit the high beam switch didn't turn it on, so I knew it was something else. I immediately grabbed my tool kit, which though cheap, thank God it was there.



I took the headlight out of the shroud, and pulled the bulb. The filament for both beams was fine. I looked at all my bullet connectors, and with the exception of a loose one, which was still making contact, all was good. Still no headlight though. I check my fuses, and all are good. Check the main (though I knew it couldn't be it), and it was fine.



So, I was ready to throw in the towel, and ride back to my mom's house on side streets, hoping a police officer wouldn't catch me, and bum a ride home. Well, I turned the key to the on position, and the headlight suddenly came on by itself. So, I left it on (didn't start it yet since I was on an incline and wanted to leave the bike in 1st gear) and geared up. I hit the start button, and the bike started just fine, but the headlight went out again. I turned the bike off vial kill switch and proceeded to start it again. Headlight is still out. I did this a few more times, and the headlight went on, and stayed on for the rest of my 12-mile ride home.



So... any suggestions on what could be the issue? To the best of my knowledge, this is the first time this has ever happened to the bike since I've owned it. Now, it did rain something fierce on Friday, and the bike got soaked since the rain started just after I got home, and the bike was too hot to cover up. I left it uncovered over the weekend, and today was my first ride since then. Maybe that has something to do with it? I mean, this isn't the first time it rained on the uncovered bike, but then, it did rain hard and it did dump a lot of water on the bike.



I know the headlight worked this morning. In fact, when I turned the key to the ON position, the headlight came on immediately (the bike faces the house, so it's hard to not notice it). When I hit the starter button, the headlight did go off, but came right back on once the bike started. I can't recall if it's ever done that before, but it's something that I noticed this morning.



Does anyone have any ideas as to what the problem could be, and would you all think I'm in the clear now, or should I continue checking stuff out? I do not claim to be good at wiring, so I will definitely need the "idiots guide" to it if that is something that I need to check.



Thanks all,

Dan
 

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ok i had the same problem one of the contacts was fubar on the bulb its self a 6 dollar fix and its great





oh i take it you want to know of the fix goto your local auto parts store and buy a new bulb and i am willing to bet that it will fix your problem
 

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Check the contacts in the plastic plug itself. I had a similar thing last year found that one of the contacts was badly corroded inside and would over heat expand and lose contact.. lights out, than would work again after turning off for a bit but than go out shortly after restarting. This took me a while to trace because the light bulb was ok, wires all ok, fuse ok, swith ok..put it all back togather and light would still go out. I had to pull the contacts out of the plastic plug clean them with a small file and sand paper, pinch them a bit so thay would grip tighter and re-insert back into the plug. No problems at all since
 

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If none of those work, check your ignition switch.



I've had intermittent headlight issues with 5 of my bikes, all but one of them were the ignition switch.

The CX500D was the only one where the issue was the starter switch (button).
 

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If none of those work, check your ignition switch.



I've had intermittent headlight issues with 5 of my bikes, all but one of them were the ignition switch.

The CX500D was the only one where the issue was the starter switch (button).


I have this intermittent issue as well, and it in fact is related to the starter button. I've blasted it with cleaner, and it has cleared up some, but occasionally will still be tempermental. A quick blip on the starer button and the light comes back on. I have yet to dismantle the button works, but that is most assuredly where my issue is.



Joel in the Couve
 

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Discussion Starter · #8 ·
Thanks guys. I'll be trying all of your suggestions hopefully this weekend, assuming the rain stays away. \



Dan
 

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Just had the same problem today, the problem was the fuse were not making good contact. I had checked them with a vole meter and they were good BUT I was making contact on the clean part. Pulled the all out and put new 10 amp fuses in and everything worked ok. Just another thing to look at, things are not as they always seam.
 

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Just had the same problem today, the problem was the fuse were not making good contact. I had checked them with a vole meter and they were good BUT I was making contact on the clean part. Pulled the all out and put new 10 amp fuses in and everything worked ok. Just another thing to look at, things are not as they always seam.


Never hurts to clean the fuse holder contacts with a few quick wipes of #400 sandpaper when the fuses are out, oxide forms there too.
 

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I have this intermittent issue as well, and it in fact is related to the starter button. I've blasted it with cleaner, and it has cleared up some, but occasionally will still be tempermental. A quick blip on the starer button and the light comes back on. I have yet to dismantle the button works, but that is most assuredly where my issue is.



Joel in the Couve


Wondering if you got to the bottom of your issue with the starter switch and the headlight. This is exactly the issue that I am having and I find that if I give the starter a quick push after the bike is running but the light is not on, then the light does come on. Did you clean the switch, and did that help?
 

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Discussion Starter · #13 ·
After reading the original ideas, I tried doing what you said works, and after I start the bike up, and the headlight doesn't turn on, a quick bump of the starter button will turn it back on. I hate doing that though.



I have not had the time since my original post do work on the bike at all. It's been sitting in the same exact place as my avitar shows, covered of course. I've been working every day since then, and have not had any time to work on this bike. I'm sure now that it is the starter switch. I just don't know if or when I'll be able to get to it this season. I may just put the bike into storage the next chance I have and just ride the little dual sport for the rest of this season.



If you happen to work on yours though, I'd be VERY interested to hear what your results are.



Dan
 

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I just fixed mine with this issue yesterday.



Take out the 3 screws on the bottom of the switch assembly (don't remove it, just open it up). Then drench the switch from any available angles with Electrical Contact Cleaner spray can and work the switch over and over. Then repeat the cleaning process a couple more times. Let it dry, and then test it while it's still open. Once working, just put it back together.



Mine works great now.
 

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I just fixed mine with this issue yesterday.



Take out the 3 screws on the bottom of the switch assembly (don't remove it, just open it up). Then drench the switch from any available angles with Electrical Contact Cleaner spray can and work the switch over and over. Then repeat the cleaning process a couple more times. Let it dry, and then test it while it's still open. Once working, just put it back together.



Mine works great now.


Excellent suggestion SiriusOp! I take it you didn't have any tiny parts scoot out of the assembly there, so that's the concern I had, and this sounds perfect.

As a note, I haven't noticed the problem return in the last several weeks, so it really seems this simple method will be a good fix.



I won't discount any of the other suggestions, such as cleaning other electrical contacts, fuse holders, and the like. If the wiring in the headlight bucket starts causing trouble, that's a whole other "ball" of wax.



Joel in the Couve
 

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No tiny parts wanted to fall out or anything. The biggest issue I had was that one of the screws refused to budge, and I ended up stripping it. So I had to drill the cap off of the screw, pull the assembly apart and turn the screw out of the upper section with a pair of vice-grips. I had to then get a replacement screw for it. (5mm X 0.80 in case anyone cares what size it was. LOL!) -- But the switch works awesome now.
 

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No tiny parts wanted to fall out or anything. The biggest issue I had was that one of the screws refused to budge, and I ended up stripping it. So I had to drill the cap off of the screw, pull the assembly apart and turn the screw out of the upper section with a pair of vice-grips. I had to then get a replacement screw for it. (5mm X 0.80 in case anyone cares what size it was. LOL!) -- But the switch works awesome now.




My headlight stopped working yesterday. I cleaned the push button starter switch. Did you clean you ignition switch?
 

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Mine ended up being the 10 amp fuse. It looked okay and I tested it with my ohm meeter and it was bad.
That thing was the first thing I tested, but it was good. After all the cleaning of the switches, I also decided to install the 30Amp Blade Fuse in-line adapter in place of the original flimsy 30Amp Main fuse. I feel so much better about having a more rugged fuse that I can buy in any gas station.
 
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