headlights not working..

Discussion in '6th Generation 2002-2013' started by warbster1, Jul 10, 2011.

  1. warbster1

    warbster1 New Member

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    Hi all,

    i have a 2004 vfr800 and recently have noticed the headlights not working. done all the normal checks... bulbs and fuses.

    the only lights that are on are the small "side light" bulbs. the "passer\flash" switch is working cos you can hear the relay working, but the headlight switch has no affect on the lights....

    i hate electrics so could do with a few ideas of what it could be before i get the multi-meter out and start taking the thing apart.....

    cheers
    Warbster1.
     
  2. stoshmonster

    stoshmonster New Member

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    No head lights at all on a 6th gen. bike is a very common problem that usually has a very simple fix Warbster.

    If all your fuses and bulbs are okay and your high beam lights DO come on when you push your flash-to-pass switch but your high beam lights DO NOT come on when you activate your light switch on the left handset and you have no low beam lights at all,then unbolt your right handset.

    Disassemble the start switch in the handset and gently clean up the copper contacts inside that switch.

    On the 6th gen. bikes the "signal" power that's used to turn on both the high and low beam headlight relays is routed through the starter switch and it exits on the the Blue wire with the White stripe.
    If no "signal" power is getting to your headlight relays on that Blue wire with the White stripe they will not be able to turn on and you'll have no headlights at all.

    Be patient and take your time when you disassemble the starter switch,it's not difficult but there are a lot of little parts inside that switch and you'll want to be careful not to lose any of them. Good Luck.
     
  3. Tiaan7

    Tiaan7 New Member

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    Hi Stoshmonster, I realize that this is a (very) old thread, but maybe you can help me out here... I have a 2004 VFR800VTEC (not ABS) and noticed that the headlights wasn't on yesterday morning, so I looked at online diagrams to find the fuse box, then tested the fuses, but they are all fine.

    When I switch the bike on, only the two very small globes come on in the front. The normal headlights stay off and the high beam also doesn't come on if I try to switch it on. I tried the pass signal too, but that also does nothing.

    How do I go about troubleshooting? I don't like to go into repair shops blindfolded, so even if it is above my level of technical works, I at least want to find the problem and see what can be done to fix it before I get ripped off in a shop. Any help is appreciated.
     
  4. Terry Smith

    Terry Smith Member

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    You might have a problem with the headlight relay, there's useful stuff in the service manual to help you through this. Here's a couple of pictures:

    [​IMG][​IMG]
     

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  5. Knight

    Knight New Member

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    Cadbury, to your knowledge on either fifth or sixth gen, does a corroded starter switch cause all lights to stop working?
     
  6. Terry Smith

    Terry Smith Member

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    The 5th gen wiring diagram shows a switch for the headlights in the starter switch housing, looks to my untrained eye that when the engine start switch is engaged, the lights are disengaged.

    [​IMG]

    The Br/Bu is +ve infeed and Bu/Wh is the outfeed that goes to the hi/lo switch on the left bar, from there to the relay and then to the bulbs. So yes I would say that corrosion in the right switchblock could cause a headlight failure.
     

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  7. Tiaan7

    Tiaan7 New Member

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    Cadbury64, thank you for the images and advice. I will have a look and see if that solves the issue and revert back. :thumbsup::mechanic:
     
  8. Tiaan7

    Tiaan7 New Member

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    Okay so I tested the two relays and they both work, then opened the right handset with much effort got the small parts out, the contacts were a bit dirty, so I cleaned them. That did not solve the issue... Any other ideas?
     
  9. Terry Smith

    Terry Smith Member

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    Nothing specific Tiaan, but I would be checking for 12v on the black/red supply to the relay and then down the wire that feeds to the bulbs when the relay is energised. Should be white/blue to the low beams, and blue/black to the high beams. You can also check for 12v on the blue (hi) or blue/white (lo) feeds that supply power to energise the relay. Just connect one end of your multimeter to the chassis, and touch the other end to the wire that you are checking, with ignition on.

    Have you checked for corrosion on the connectors for the bar switches?
     
  10. Djee

    Djee New Member

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    Tiaan, I have had a similar problem...and came from the light connectors that appeared to have corroded and overheated. The connectors that connect right into the bulb. Changed them all 4 and no more problem now.
    Good luck
     
  11. ellewasal

    ellewasal New Member

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    I have done all that before. It has just happened again and it was not the contacts. The starter button return is weaker than it needs to be. If you just flick the starter back to its rest position after starting, and the lights start working as normal then you will know that's the issue. I am putting this up now, because until I read this thread again I had forgotten that the starter circuit was involved, though its obvious because the lights switch on at start. A bit of lube and its sorted for time being. Hopefully this may save some poor wretch from unnecessary dismantling
     
    One Ida 31 likes this.
  12. SpikeM

    SpikeM New Member

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    Hi, I'm resurrecting this old thread as I have a similar issue, but not exactly the same on a 2005 VFR non abs. No dip or main beam. Flash/pass also non operational, although an audible click can be heard. Parking/side lights operational. Starter button does not seem 'sticky' and returns fully. Although I have not removed any of the bulbs as yet, on close inspection the filaments appear to be fine ( it's highly unlikely all four bulbs would have blown?). Fuse fine and swapped just in case. Should I be looking at the relays, starter switch or something else before I start dismantling? Any advice greatly appreciated.
     
  13. Grum

    Grum New Member

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    Break out the circuit diagram and voltmeter, check the voltage of the Lo beams probing the lamp sockets. Make sure you are seeing 12v between the White/Black wires and the Green ground wire for both Lo beam lamps, ignition to On.

    Hearing the Hi Beam relay click on and off when operating the Flash/pass switch means that the auxiliary contacts of the Starter Switch are working. SORRY - Post edit THIS COMMENT IS ONLY RELEVANT TO THE DRAWING SUPPLIED IN LOWER POST! THE DRAWING DOES NOT HAVE THE FLASH/PASS SWITCH, AMERICAN VERSION.
    If your bike has Both Hi/Lo Dimmer switch AND a Flash/Pass switch then you still may have an issue with the Starter Relay auxiliary contacts, this is because the power from the Flash/Pass Switch operation is NOT through the Starter Switch, whereas the Hi/Lo Dimmer switch is through the Starter Switch auxiliary contacts - Sorry for any confusion.
    In other words - Operating the Flash/Pass switch should always activate your Hi Beams, irrespective of a good or bad Starter Switch.

    If you are missing the 12v at the globes follow this back to the relays. Make sure you measure 12v on the Black/Red wire on both Hi and Lo beam relays. Also confirm the globes Green ground wire has continuity (virtually zero ohms) back to the battery Negative terminal.

    And Yes it is possible for all four bulbs to have blown, especially if you have developed a fault with the R/R and your charging voltage is high, so also check what voltage you are seeing at the Battery with the engine running at idle and 5000rpm at normal engine temps.

    Let's know how you get on with above checks.
     
    Last edited: Sep 22, 2022
  14. SpikeM

    SpikeM New Member

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    Many thanks Grum for the info. I was going to start by dismantling the starter button, but what you're saying makes perfect sense as the flash/pass switch definitely does cause a click, so current must be passing to the main beam relay. So it's looking like a faulty dipped beam relay. Don't quite understand, given there are two separate relays, why the main beam doesn't work even if the dipped beam relay is faulty, but I can only presume the two are somehow linked.
     
  15. Grum

    Grum New Member

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    Do not presume/guess anything this is very poor fault finding, work with your bikes wiring diagram and always measure! The headlight system is not a complex one, logical following of the voltage from headlights, through the relay contacts back to your lighting fuse should hi lite where your voltage is missing (assuming the lighting Grounds are good). Don't discount the possibility of all four globes blown if you confirm voltages and grounds are good at the back of the globe sockets!

    The common thing between the two relays is the switched power source for all 4 globes being the Black/Red wire from your Lighting Fuse to both relays. AND the weakest link for that wire is through the Blue 18p connector. Depending on your bike configuration you may have only One Black/Red wire passing through the Blue connector, this would make the connection through the Blue 18p connector highly suspicious as ALL globe current is through this one pin and socket connection, or as per the drawing attached, Two Black/Red wires, sharing the Hi and Lo beam current.

    Measure voltages to find what is missing. Hopefully the attached colorized drawing may help you, but it may not be exactly per your bike. SORRY AMERICAN VERSION SHOWN - DOES NOT HAVE THE FLASH/PASS SWITCH.

    Good Luck, lest know how you get on.
     

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    Last edited: Sep 22, 2022
  16. Grum

    Grum New Member

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    PLEASE read my edit to my first post - Your bike having the Flash/Pass switch (like our Australian versions), YES - you still may have an issue with the Starter Relay auxiliary contacts if your Lo beams are not illuminating. The Flash/Pass switch operation is not effected by the Starter Switch contacts.

    You are hearing the Hi Beam Relay click when you operate the Flash/Pass switch so your Hi Beams SHOULD be illuminated while holding the switch On. If NOT then this could mean blown globes, faulty relay OR as mentioned, the 12v from the Black/Red wire is missing!.
     
    Last edited: Sep 24, 2022
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