[Jarrett]

Alright, this is now the second time I've had headlight issues on my 2002 750. The first time it was the infamous corroded connector in the right fairing. That would cause my headlights to stop working all together which was really scary at night when it would go out. I fixed that by jumping that connector because cleaning the connector still didn't want to work. So, that fixed it for about a year and a half. Today I got up at 7:00 to go to class and everything was fine. I drove around a little later and my high beam indicator LED was not on in my gauges. So when I got home I checked it out and sure enough my high beam bulbs were not on. I tried low beams and that worked just fine. I took the front fairing off and replaced the bulbs. Same issue with the replacement bulbs(which were actually the factory bulbs). I changed the fuse and that didn't work either. I wiggled the connector that I had previously jumped and still nothing. I am completely at your mercy. I need help.

Jarrett

 

[Lucky-Gixxer6]

So when I got home I checked it out and sure enough my high beam bulbs were not on. I tried low beams and that worked just fine. I took the front fairing off and replaced the bulbs. Same issue with the replacement bulbs(which were actually the factory bulbs). I changed the fuse and that didn't work either. I wiggled the connector that I had previously jumped and still nothing. I am completely at your mercy. I need help.

Jarrett

Why not try reading the voltage?

 

[Jarrett]

My voltmeter is broken.

 

[Jarrett]

Bump, please!

 

[Jarrett]

Well it doesn't look like anyone has had similar issues but if anyone cares I did some further playing with it today cleaning the terminals on the yellow connector on the right side that I had previously jumped and checked the soldered connections on the specific wires that I jumped and still nothing happened so I'm thinking I can rule that out. Could this possibly be the headlight high/low beam switch on my left handlebar? This bike does see rain from time to time so is there a possibility there's an issue in there? Still kind of frustrated by this problem because I use my high beams often because of so many close encounters.

 

[Jusone36]

i would like to know...hubby's having same issue...

 

[Jarrett]

I wanted to add one more bit of info. The bulbs that it's had in there for about a year and a half now are eBay bulbs that are 90W. I just wanted something that would put off a little more light than usual. But keeping on mind that my low beams still work could my harness be melted?

 

[gixxereater]

If it sees rain.....I've had the left switch from hi/low get junky and simply cleaning with with contact cleaner worked great!
Just a thought.
It would not work when switching to hi and sometimes playing with it to make a connection would work, eventually it stopped altogether..........it's easy enough to clean. Give it a whirl.

 

[Jarrett]

I did open it up and saw no signs of corrosion. Did yours?

 

[badbaby]

The bulbs that it's had in there for a year and a half now
are eBay bulbs that are 90W.

You should have mentioned the 90-watt bulbs to begin with.
The first thing you need to do is remove the 90-watt bulbs,
throw them in the trash and never use them again.

Haven't you noticed how flimsy the headlight wiring is on
these bikes? I can't say for sure you've damaged your
wiring or connectors by using those high-wattage bulbs,
but get rid of them. Don't use a bulb that's more than
65 watts or so.

I'm no expert on electrical problems, but Daniel Stern is.
Go to his website, scroll down to the bottom of the page
where it says "click here to send e-mail" and send him an
e-mail describing your problem. He likes to give personal
service to customers, so don't be shy about sending him
an e-mail.

Be sure to tell him you've been using 90-watt bulbs, and
tell him the type of bulb that's supposed to be used in
your 2002 model bike: 60-watt H-4 bulbs, right?

He can probably sell you some type of headlight wiring
kit that will bypass your stock wiring, and his kits are
pretty cheap as I recall.

If you rewire your headlights with heavy-duty wiring
and a kit from Daniel Stern, you might be able to use
your 90-watt bulbs, but don't use them with the flimsy
stock wiring. Anyway, see what Daniel Stern says.

 

[Jarrett]

Thanks for the info. As for the 90W bulbs, I purchased them not knowing they were 90W bulbs. The incident that happened a year and a half ago that I mentioned in my first post is what made me buy new bulbs...at that time not knowing the harness was the issue and trying to rule out just my bulbs being burnt. I got them from eBay knowing I was buying falsely advertised H.I.D. bulbs but just hoping the different light color would be an upgrade over the stock bulbs. Immaterial because they didn't solve the real problem. Anywho I sorted all that out when I jumped the harness plug under the right fairing so.....on to the current situation.

I don't want to buy an "upgraded" harness because I just want the stock lights(or at least stock wattage) back in there and the bike to operate as it was designed to. But again, thanks for the information and I will e-mail him to see if he thinks it's my harness.

Also has anyone on here ever had high beam issues in which the blue LED indicator remained functional? This is now the second lighting issue I've had where that has stopped working as well. I was just trying to narrow things down. Thanks.

 

[Jarrett]

Badbaby, I e-mailed him that day and still haven't gotten anything back. Does he normally take this long to respond to inquiries?

 

[badbaby]

Badbaby, I e-mailed him that day and still haven't gotten
anything back. Does he normally take this long to respond
to inquiries?

When I e-mailed him, he got back to me the same day.
I don't know why he hasn't gotten back to you.

 

[Jarrett]

Oh well, I ordered a set of bulbs that are 55W/60W so they should be in soon and I'll see if this solves the problem.

 

[Jarrett]

Sorry to keep boring everyone with this thread but I'm just hoping to find someone who can help. I just put the new bulbs in that I ordered and I'm still experiencing the same problems. I can't get this freaking high beam to work!

 

[wildinout29]

You should have mentioned the 90-watt bulbs to begin with.
The first thing you need to do is remove the 90-watt bulbs,
throw them in the trash and never use them again.

Haven't you noticed how flimsy the headlight wiring is on
these bikes? I can't say for sure you've damaged your
wiring or connectors by using those high-wattage bulbs,
but get rid of them. Don't use a bulb that's more than
65 watts or so.

I'm no expert on electrical problems, but Daniel Stern is.
Go to his website, scroll down to the bottom of the page
where it says "click here to send e-mail" and send him an
e-mail describing your problem. He likes to give personal
service to customers, so don't be shy about sending him
an e-mail.

Be sure to tell him you've been using 90-watt bulbs, and
tell him the type of bulb that's supposed to be used in
your 2002 model bike: 60-watt H-4 bulbs, right?

He can probably sell you some type of headlight wiring
kit that will bypass your stock wiring, and his kits are
pretty cheap as I recall.

If you rewire your headlights with heavy-duty wiring
and a kit from Daniel Stern, you might be able to use
your 90-watt bulbs, but don't use them with the flimsy
stock wiring. Anyway, see what Daniel Stern says.

Stupid quesition...

I know alot of people who use their stock wiring to run HID's and i'm pretty sure that they well over 65watts and they never had a problem.

 

[wildinout29]

Sorry to keep boring everyone with this thread but I'm just hoping to find someone who can help. I just put the new bulbs in that I ordered and I'm still experiencing the same problems. I can't get this freaking high beam to work!

You need a multimeter...have you checked your fuses?

 

[Jarrett]

Yes I've changed my fuses and my voltmeter LCD is broken. I'm going to try to clean out the black connector tomorrow because according to the wiring diagram one of the high beam wires runs through there. I just need to go to radio shack and see if they have any spray electric cleaner.

 

[Chopstick80]

Well, based on what you have said I think the first thing you must do is get a multimeter. It's vital in troubleshooting this issue. If you don't want to buy one since yours is broken, get a small 12v test light.

I don't have a 2002 but my guess how it works is Battery -> Fuse -> Switch and then parallels to Blue Indicator light and Hi Beam. Since both your Hi Beam and indicator both do not work it has to be either the wiring harness after the fuse, the switch itself, or the wiring after the switch.

This is where the multimeter is critical. You can then test to see if the voltage is even reaching the switch. If it is, then you know it can be the wiring from the switch forward. Then check the switch and the wiring after that. Now, the switch may actually turn on a relay. Like I said, I don't have a 2002 so I don't know for sure, but it's easy to just follow the wires. If it does, see if voltage is coming out of the relay when the switch is turned on.

I'm pretty confident that it's not the bulb itself and it's not the indicator itself. I think the switch itself could be dirty, or fried the wiring harness somewhere you can't see. This is why it's best you get a meter. You can see where the voltage starts and where it stops. Once you figure out where it stops, you found your answer. Like I said, if you won't want to spend the money, get a tiny test light, they're cheap.

Let me know if you figure anything else out.

 

[Jarrett]

Thanks a lot for the suggestion. I did find my Fluke meter last night but I think the fuse is bad in it but I think that only works for measuring amps. I might be mistaken on that though. But yeah, to clarify on what you said about it not being the lights I can guarantee that it's not the actual bulbs because 3 different sets have been in there and all 3 have done the same thing. /Thanks again.