Dead Headlight & Horn

[Nightflight99]

My 2001 Standard has had some intermittent turn signal issues (they would work sometimes, other times not), until recently, when they almost never worked. I first cleaned the inside of the turn signal switch housing (no effect), then checked the relay and found that it was not clicking. Ordered a replacement (due to arrive later this week), and was satisfied that the issue was about to be fixed.

Late last night, as I was about to make an-hour ride home, I hit a bump and the headlight (and horn, as I figured out later) died instantly. Couldn't get it sorted on the road (it was cold as heck), but was able to dig into it in the garage this morning. I checked the fuses -- no issues (tested with new fuses, just in case). Took the turn signal switch apart again, just in case I missed something the first time, but nothing. Since its both the headlight and the horn (and of course the turn signals, although I still think that they are a separate issue), I'm hopeful that this is something relatively straight forward.

Any suggestions would be appreciated.

[The emperor has no clothes]

I don’t know if the starter switch affects the horn and turn signals also, but it’s certainly worth cleaning up to rule it out.

https://www.rattlebars.com/mtz/starter.html

[Clarkcelt]

Since its both the headlight and the horn (and of course the turn signals, although I still think that they are a separate issue), I'm hopeful that this is something relatively straight forward.

Any suggestions would be appreciated.

I recently removed a Cobra light bar, and the wiring in the headlight bucket had several connections which were cut to use for the light bar. A brown wire with a white stripe was cut in two.

I really have no idea, but I would check the wiring inside the headlight bucket, to make sure you don't have a loose wire or two.

[dago mooserider]

I don’t know if the starter switch affects the horn and turn signals also, but it’s certainly worth cleaning up to rule it out.

https://www.rattlebars.com/mtz/starter.html

Definitely check the starter button. I had a similar thing happen and it was my starter button. I was on a pitch black very cold mountain road and bout had to change my shorts. With key on try to jiggle it up and down and see if the light comes on. Crud or contacts worn

[rug_burn]

Sometimes these weird groups of electrical devices not working is due to an open, or unconnected ground somewhere.   I fact sometimes you'll get a situation, for example like on my truck, where I hit the horn button, and the dome light comes on, and the horn only kind of buzzes.  their ground wires are all connected, but are not connecterd to ground sufficiently... so they energize various other devices partially.

[Peteg]

The horn and headlight have common ground on my wiring diagram. Pull you head light and separate the 9 pin red connector maybe just plug it back in, and see if the problem goes away. Your problem is in the green wire. Check continuity between the head light  ground pin and the green pin in the 9 pin. If good check from the other green pin to battery ground. This will tell you which wire is broken if not immediately apparent. If you can't find the break, jump it out with alligator clips. Once you get it working install a permanent jumper. Hope this helps, good luck.

[Nightflight99]

Thanks for all of the suggestions -- much appreciated.

I dug into the bike, and was able to fix the headlight. It turned out to be a burned up connector (looks aftermarket, probably from the previous owner when the LED headlight kit was installed) inside of the headlight bucket.

I also figured out that the dead turn signals were not due to a bad turn signal flasher relay after all, but were instead caused by a bunch of build-up inside of the turn signal switch at the handlebar. I had to completely disassemble the switch to get to the problem. Works like a charm now.

The horn is still not working, hope to tackle that over the next few days.

[Peteg]

It looks like you can check the horn circuit from that 9 pin red connector behind the head light. The first thing I would do is check to see if the horn reads open. Since your turn signal switch was dirty, there's a good chance it maybe the horn switch, but if it's not obvious start testing at the 9 pin. The 2 horn wires from the switch appear to be green and purple & black. The mating wires to the horn or bike appear to be black. So with a good fuse and horn and the ignition on, and the 9 pin connector open the two black wires should have 12 volts. With the horn switch held closed the green and purple & black should read 0 ohms. If there is a broken wire, you can use the same logic to trouble shoot. To check the power wire, pull the horn fuse and check resistance from the output side of the fuse holder to the black leads on the 7 pin. Do the same to the battery negative. If both wires are good you will get zero ohms on two wires and know which is power and which is ground. You can ring out the horn switch wires the same way, between the horn switch and the green and purple & black. You will probably find the problem before you have to ring out the whole circuit, but broken wires are pretty easy to find. I have to find broken wires on my Triumph all the time.

[Pluggy]

Before disassembling the bike.... Have you checked for voltage on the two wires at the horn?

[Peteg]

Good point Pluggy! I didn't even walk out and look at the bike - it's freezing. Checking the horn and the horn switch is easiest and most likely.

[Pluggy]

Good point Pluggy! I didn't even walk out and look at the bike - it's freezing. Checking the horn and the horn switch is easiest and most likely.

Motorcycle horns take a beating and ingest water and dirt along the way. Even the good ones tend to give up early.  One of the least reliable motorcycle parts.

[Peteg]

Just braved the cold and walked to my shop. Probably the easiest first step is pull the horn connectors. If you get 12 volts with the horn switch pushed and the ignition on the switch and wires are good. I agree  it's most likely the horn. Merry Christmas.

[Nightflight99]

And the horn it was! Got good voltage at the horn with the button pushed. Wired up some random non-Valkyrie OEM horn that I had laying around until the new Stebel Nautilus gets here.

Thanks for everybody's input! I appreciate it.

[Pluggy]

Mr. Nightflight... You may know this already.  You have pirchased an extra powerful horn.  Stebel instructions show how to connect the horn through a relay.  Installing one the same way as the stock horn will likely blow the fuse.  Use and enjoy!

[Nightflight99]

Horn was successfully installed. Its quite the unit compared to the OEM horn.

Thanks for all the suggestions and feedback!