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Old January 27th, 2019, 07:10 PM   #1
achimedes
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Headlights dont work ever after replacing battery

I just bought a new battery because my bike wouldn't even try starting and the headlights weren't turning on. The blinkers and dash lights, however, do work.

If the new battery is in perfect condition, what could be the problem? My bike had been sitting for ~1 month because it was knocked over and I was getting it fixed back up. Initially after falling, the bike was able to start (only tried the one time), but after a few weeks it stopped.
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Old January 27th, 2019, 08:27 PM   #2
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One of the safety switches most likely.
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Old January 27th, 2019, 08:49 PM   #3
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If not a safety switch, check the ground wire where it bolts to the motor, make sure it's clean and tight. Head light won't come on until the engine starts.
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Old January 27th, 2019, 09:08 PM   #4
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Thanks for the replies guys. Is there a wiring diagram or somewhere that shows where the safety switches are located?
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Old January 27th, 2019, 09:10 PM   #5
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what year is your bike? I'm guessing it's a new gen, at the top of the 2008-2012 tech page is a stickied link to the wiring diagram.
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Old January 27th, 2019, 09:23 PM   #6
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2012. I'll look for it
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Old January 27th, 2019, 09:40 PM   #7
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the links at the beginning of the thread don't work, but if you scroll down, there are pics posted.
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Old January 27th, 2019, 09:51 PM   #8
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Note that headlights won't turn on until engine is cranking fast enough to activate headlight relay from stator coils. Basically headlights won't turn on until engine's running.

Not starting can be power not reaching starter solenoid. Many segments of wiring can cause break and no starting. Measure for +12v at each of following points. Where +12v disappears is problem (or just before).


battery +terminal -> 30a fuse -> W wire -> ignition switch ON -> BR wire -> 10a IGN fuse -> BR/BK wire -> Y/R wire -> stop switch ON -> R wire -> BK/R wire -> start button ON -> BK/R wire -> diode B -> BL wire -> starter circuit relay -> Y/R -> starter solenoid

There is also ground side of circuit with interloc safety switches. We'll deal with that next if you find that +12v makes it all way to starter solenoid.
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Old January 27th, 2019, 10:16 PM   #9
achimedes
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I'll work on this tomorrow then give yall an update
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Old January 30th, 2019, 03:13 PM   #10
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@Z1R rider

Is this the ground wire I should check??

I took a multimeter to the bike and found that the battery is good. Likely didn't need to buy a new one but o well. I gave them my old one so no returning it, if they even accept returns.

I wanted to check the other connections but I was pretty helpless with a multimeter. Didn't know the first thing about checking connections. I'm going to watch some youtube videos then give it another try.
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Old January 30th, 2019, 09:08 PM   #11
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That's the one I was thinking of, but you want to make sure that ALL the connections, + and - terminals on the battery are also clean and tight as well as the relay that the + cable goes to.
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Old January 31st, 2019, 08:11 PM   #12
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Quote:
Originally Posted by achimedes View Post
I wanted to check the other connections but I was pretty helpless with a multimeter. Didn't know the first thing about checking connections. I'm going to watch some youtube videos then give it another try.
Here you go!

https://learn.sparkfun.com/tutorials...multimeter/all

Link to original page on YouTube.

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Old February 1st, 2019, 12:42 PM   #13
achimedes
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Thanks for the video

On this wiring diagram
, how do I identify the safety switches? How many are there that I need to check?

If you squint you can see I added a pink highlight over the wires that connect to the starter button box.
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Old February 1st, 2019, 12:48 PM   #14
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Look for:

1. neutral switch
2. sidestand switch
4. starter lockout switch (clutch)
5. engine stop switch (kill).
6. diodes

These form series (in row) circuit that any one of them can interrupt. Final result is:

Do you have ground at starter relay's coil?
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Old February 1st, 2019, 12:53 PM   #15
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I think you also might want to think about checking the stator.
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Old February 4th, 2019, 12:08 AM   #16
achimedes
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I got it working! I made a short video with the solution. Turns out there's a little button that's normally pushed in when the clutch isn't engaged. For some reason, my clutch was very loose and the button wasn't being pushed in, so the bike wouldn't start.

Thanks everyone for the help!
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Old February 4th, 2019, 06:04 AM   #17
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glad you found it.
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