I need some help with headlight install. Thanks
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Tourer
Joined: Jul 2010
Posts: 426
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From: Annapolis, MD
I need some help with headlight install. Thanks
I'm changing out my headlight and having trouble with the wiring. The headlight has 3 wires which is the same number as the harness coming from the bike. I spliced what appears to be the matching neutral wires together and then the other wires and the bulb lit up when i turned the key. Just out of curiosity i left the neutral together and then reversed the two other wires. The light still lit up. So i put them back to the original configuration, solder etc and the light is still working. When i mount it to the bike and turn the key, however, it blows a fuse. I took it apart, reversed the wires and the result is the same. As soon as it gets mounted, it blows the fuse. I don't know enough about electrical to figure this one out. I assume it has something to do with a faulty ground but I don't know how to fix it. I bought a multimeter but have never used one so any advise would be great on how to get the wires right to complete the circuit.
Road Warrior
Joined: Apr 2010
Posts: 1,739
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From: Suffolk, England
Could be you have the ground and one of dipped or main reversed. The lamp will light out of the bike even with the current running backwards through the lamp. However, the shell of the light is now live so when you put it into the bike the live light contacts the bike's frame and so the fuse blows.
Thread Starter
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Tourer
Joined: Jul 2010
Posts: 426
Likes: 2
From: Annapolis, MD
Thanks, that solves half of the problem. Now at least i know where i'm starting from
Thread Starter
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Tourer
Joined: Jul 2010
Posts: 426
Likes: 2
From: Annapolis, MD
Could be you have the ground and one of dipped or main reversed. The lamp will light out of the bike even with the current running backwards through the lamp. However, the shell of the light is now live so when you put it into the bike the live light contacts the bike's frame and so the fuse blows.
sounds very possible. Now the question is how do i determine which wire from the headlight is which without splicing every possible combination? The headlight wires do not match the yellow, white, black coming from the bike. As i mentioned, i have a multi-meter but have not had to use it so i'm not sure how to run the test on the headlight wires
Road Warrior
Joined: Apr 2010
Posts: 1,739
Likes: 10
From: Suffolk, England
sounds very possible. Now the question is how do i determine which wire from the headlight is which without splicing every possible combination? The headlight wires do not match the yellow, white, black coming from the bike. As i mentioned, i have a multi-meter but have not had to use it so i'm not sure how to run the test on the headlight wires
Lets say the three wires from the light are red, green and blue (substitute the correct colours here).
Check for some resistance between pairs of wires, R-G, R-B & G-B. Two of these pairs will pass current and one won't. The common colour between the pairs that pass current is the ground. Example, if R-G and G-B pass current then G is common to both so the ground is G (green).
Finding the dip and main is trickier. I'd do it by trial and error. If you have a spare vehicle battery its easier, otherwise you'll need to use the bike's.
Stand the light somewhere its beam can shine on the wall and have the ends of the two non-ground wires bared.
Connect the ground you just found to the battery's neg with a bit of wire.
Then connect another wire to the battery's positive terminal and tap the other end on one of the headlight wires. Note the pattern the light makes. Tap it on the other wire. It should be fairly obvious which is then the main and which the dip wire.
Last edited by Foxster; Jul 17, 2012 at 11:01 AM.
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