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
     
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