Interstate headlights

[Jess from VA]

Please refresh my recollection guys.

My favorite Interstate had a long term issue of one of the two headlamps not coming on at startup.

I'd swing the forks and reach up in there and push on the plug and on it came; almost always for the rest of the day.

When I had it into my ace mechanic last time I asked him to clean up the contacts/plugs, and since then the problem disappeared (for months).

Today, I had no dims at all (brights working fine).  Pushing plugs did nothing.

I recall there's a headlight fuse, but not separate fuses for dim and high, right?  Electrical is not my strong suit. 

The bike came with two sets of extra forward lights (Motolights (35 watt) down by the axle, and PIAAs (55 watts) on the fork wings).  So I ran the Motolights, rather than the brights.

Any thoughts or suggestions on why I lost both dims together?  Bulbs are upgrade and only a couple years old.

I went for a short ride this morning.  They said it wasn't supposed to rain until this afternoon.  They lied. 

[old2soon]

     Jess try removing the plugs and put a slight Outward tension on all 3 male contacts. Also check and make SURE those contacts were indeed cleaned. RIDE SAFE.

[Jess from VA]

Thanks Dennis, but I just don't see both headlight connections/plugs going at the same time. 

Tomorrow morning when it's cooler, I should take a look at the hi/low switch.  Not that I know what to look for in there.  Probably little spring loaded parts that will fly way. 

[Jims99]

I would think high low switch. You can soak it with wd40 and rock it back and forth a bunch, that should help clean it up. If you do take it apart to clean, do it in a plastic bag, then if the spring wants to take off it’s much easier to find.

[Jess from VA]

Yes on the plastic bag trick.  Thanks Jim.   

[Jess from VA]

Well, this morning I took the left handlebar switchbox apart and pulled the dimmer switch out, and sprayed electronic cleaner/lube spray and worked the switch, and blew it off with canned air.  I did not pull the wires, but they appear good and secure.  The switch seems good with positive clicks dim to high.

I pulled the sidecover, and the 5A headlight relay fuse is good.

I still have two good brights and no dims.

I'm at a loss.

Looking at the factory manual, I see a "headlight low beam relay" but did not locate it.

Could some kind of power surge blow the headlight bulb dim filaments (only) out at the same time?  I hate pulling the bulbs up under there. 

Any ideas guys? 

My ace mechanic is an hour away and always swamped.

Yesterday, I just rode with the brights all day (maybe a good idea anyway), and the charging system didn't seem to mind (I always try to use minimum power draw).

[Jess from VA]

So I called my local (huge) metric dealer, and no one in parts dept can find an interstate "headlight low beam relay (4P-brown)" in any interstate parts fish.  I'm thinking the "4P" means 4 prong, and brown for brown wire????)

The guy told me the parts fish had 4 "starter relays" listed and one of them is probably the one I may need.  He says this happens all the time in metric bike parts fishes for the small electrical parts.

I don't know if my low beam relay is bad or not, I dug in there and tried to find it ahead of the ICU.

I give up, and will take the bike to someone who knows what he's doing.  

Good thing I have 2 bikes (the no dim bike is running fine).

I think it's the relay, but it's only a guess.  

[NewValker]

Hey Jess, I know it sounds out there, but maybe both bulbs died close to the same time?
Since I went to Sylvania bulbs, I’ve replaced one or the other every couple of years. Mostly due to our pothole filled roads, hit a bad one, and next day or so I notice 1 out. And always the low beam.
Maybe grab one at WW and switch it out? Could be quick and easy fix??

Craig

[Jess from VA]

Thanks Craig.

I hate changing interstate bulbs.  You can look, or work, but you can't look and work.

I stuck in high quality Hella 80/100s in both interstates a few years ago, and have had no trouble (only ever run dims).  The interstate fairing breathes/cools way better than the Std/Tourer bucket.  No other extra power draws.

It just seems very unlikely I'd blow both low filaments at the same time (from some kind of surge?).  I know it's possible.  

I've already asked for an appointment with my ace mechanic (an hour South).  

The other bike needed ridden anyway.  

[Jess from VA]

So today I get home from a ride on my lower mileage interstate (that has never had headlight trouble), and when pull in, I have no headlights dim or bright.  WTF?   

I checked nothing and put it away.  Need cooler temps in my backyard.

[Jims99]

That could be the start button. Kills the headlight when pushed in. These issues are usually simple, just need to track it down.
Did you ever get the other bikes headlight fixed?

[Jess from VA]

That could be the start button. Kills the headlight when pushed in. These issues are usually simple, just need to track it down.
Did you ever get the other bikes headlight fixed?

Thanks for responding Jim.

No, the other higher mile bike (both '99 Interstates) lost both dims (same time), has both brights.  I did my best, cleaned the hi/lo switch, and thought it might be the low beam relay, but I couldn't find it, and the Honda dealer says it isn't even in the parts fish (to buy one, and then look for the same thing on my bike and replace, to rule in or out).

A week after the other lower mile bike passed my state inspection (including lights), I got home yesterday with no headlights at all.  They may have been out all day; I don't usually check them before riding.  I did run over two dozen RR tracks yesterday, I slow but not to a crawl.

As I said before, I (my mechanic) replaced all 4 headlight bulbs (both bikes) some years ago with Hella off-road 80-100s (run dims constant, never brights except an occasional flash).  I've never had any problem over the years (6-8?), but this happening in both bikes in close proximity has me thinking it may be the higher draw bulbs.  

I hate changing interstate bulbs; sometimes I can get one in in a half hour, and sometimes it's hours of cussing.  I watched my mechanic put a lawn chair in front of the bike, sit down and reach under and do it all by feel (in seconds).  I always worked from behind the fairing, kneeled down reaching up and in.  I wish my mechanic wasn't an hour away and always swamped (because he's the best).

First I need to rule out the 5A headlight fuse.

Then I need to buy 4 std auto parts 55/60's and start pulling and inspecting bulbs.... and I dread it.

My higher mile bike came with two sets of aftermarket running lights forward (35W Motolights down low on the forks, and 70W Piaas on the fork wings (both working), and I could just run that bike with one of them on.  But that's not going to fix one damn thing.  

[Slyk Willy]

 

"I hate changing interstate bulbs; sometimes I can get one in in a half hour, and sometimes it's hours of cussing.  I watched my mechanic put a lawn chair in front of the bike, sit down and reach under and do it all by feel (in seconds).  I always worked from behind the fairing, kneeled down reaching up and in.  I wish my mechanic wasn't an hour away and always swamped (because he's the best)."

I've seen it done once. I couldn't do it then or now. I've removed the fairing giving me the opportunity to clean things and replace bulbs. I use SilverStar auto lamps. They've worked for years now.

[Jess from VA]

Well, the lower mile trunk bike only needed a 15 amp headlamp fuse (under the side cover) to fix.

(Unless I keep blowing fuses.  Rain today, so no shakedown test ride.)

As soon as I was done, I went to the other bike and checked the same fuse.  I had already done that, but hope springs eternal (it was good).  Then did a forehead smack... that bike only lost both dims, if that fuse was blown, I would have no headlights at all.  Doh. 

My next question is why did I blow the 15 amp headlight fuse on my trunk bike?   I suppose I have blown a couple fuses in 20 years of riding these two bikes, but damn few.  So it makes me suspicious.  IF they don't keep blowing I suppose it's all good. 

I carry a pile of good fuses, but that's no way to run a railroad. 

[3W-lonerider]

because of the leg being melted like that. i would say you have a bad connection in the fuse holder. i would say if you don't try and tighten that connection. its going to happen again.
you might be able to shove a tiny screw driver on the outside of the female connection to get the opening to tighten up alittle. if there is no drag on that connection it is gonna arc in there.

[Jess from VA]

because of the leg being melted like that. i would say you have a bad connection in the fuse holder.

Thanks man, but that picture is random from the interweb (not mine).  My fuse had no damaged leg, just a small break in the wire. 

[Mooskee]

Before I switched my car headlights to LEDs, I had both sides high and low beams out at once. Hence my switch to LEDs.

It is a pain to pull the fairing, but probably as fast, and easier than fighting those bulbs blind.

[Mooskee]

I just checked the schematics. There is a Headlight relay Low, and  Headlight Relay High. They are listed as Under the Seat. The Low one has  brown 4 pin plug. The high one has a 4 pin black plug.
There is also a 15 A fuse for headlights, and a 5A fuse for Headlight relays. They are in the fuse box under right cover.

If you want the colorized schematics, they can be downloaded from my website. www.valkyriecarbsandcustom.com

[Jess from VA]

There is a Headlight relay Low, and Headlight Relay High. They are listed as Under the Seat.

They're buried well under the seat.