HeadLight Fault Help

[ChainBlueLightning]

Hi everyone I think I have some kind of connection problem for my headlights and was looking for some advice as to a solution. I didn't really want to take it back to the dealer I bought it from as they have been less than helpful everytime I go.

Basically I set off in the dark last night everything seemed normal witht my lights, I pulled onto a country lane and put my full beams on.. everything still okay. As a car came the other way I dipped my lights and after the car passed me I was riding in pitch black! I had to pull up in the next lay by. My tiny sidelight were working but both my headlight bulbs were out, I thought it was odd they both went together? but my full beams worked perfectly. After killing the ignition and staring my bike flicking through all the settings of lights and messing witht he connections tot he rear of the bulbs nothign seemed to work so I thought I better go home. as soon as I set off again my headlights worked fine! Then this morning coming to work my headlighs worked fine in the garage but as soon as I set off cut out again? by the time I got to work 10 mins later they seemed to be on again?

has anyone else encountered a similar problem or can suggest what I could try. I'm not great with electrics. all I can think is to clean all connections and change the bulbs. but that doesn't seem to help me in the slightest.

anyone give me any clues to my gremlin?

thanks

[MartinW]

You won't need to change the bulbs as they clearly do work sometimes.

Sounds like either one of the connectors up behind the radiator or a problem with the hi/lo handlebar switch. Try cleaning them both.

Put a bike model in your profile as it will help one of the "real experts" to propose other potential causes.

[greywolf]

On 2005 and later models, the contacts on the headlight cut out switch section of the start button are by far the most common problem. Earlier models don't have a cut out switch. Following that, the contacts in the connector in the left side of the fairing or behind the radiator top shroud may have a problem. The hi/lo switch itself can be the problem but that's rare. http://www.stromtrooper.com/information-vault/71046-headlight-problems.html

I recommend installing headlight relays to head off the problem but once it occurs the damage has to be sorted first.

[V-Strom3]

This is well documented on here I think it's bigpie?? ? who makes headlight relays that plug straight in, basically the power is taken via the relays instead of the original wiring, but the original wiring still operates the light switching.

[ChainBlueLightning]

ahh sorry my info used to be on my profile before the forum update.

my bike is a DL650A 2014

I'm liking the sound of the cut out with the start button. I'll have to wait till the weekend to properly investigate but thanks for the help. It just seemed strange to me after I cleaned all the contacts that the small sidelights still work regardless but they still cut out with the start button. Small electrical problems are the worst for me!

lets see what weekend brings

[UK_Vstrom650]

Isn't your bike still under warranty..??

[ChainBlueLightning]

no

[user650]

I thought they all had a two year warranty 

[UK_Vstrom650]

They do have a two year warranty hence the question. I'd just to the nearest Suzuki dealer and have them fix.

All EU spec bikes come with a two year warranty which transfers with the new owner.   https://www.Suzuki-gb.co.uk/ccr/customer-services-frequently-asked-questions/#FAQ_WARRANTY

[ChainBlueLightning]

Its not covered by the warranty they told me nor was the head bearing and chain and sprocket set I needed after 10 months either as its all vaguely considered "general wear and tear" and not included in the warranty

[Hondaman]

Bollox.

C&S is a wear item fair enough, wiring, switches, controls etc most certainly should be covered.

Go back and be a little more forceful....

[MartinW]

+1 - Anything to avoid a warranty payout isn't it.

[alibx11]

Did you check the 15a low beam fuse?, I know it works sometimes but could be a bad fuse or faulty connection there.

[UK_Vstrom650]

Absolute crap. You need to either try another dealer or go in the showroom when there's customers in there and ask in a loud voice why they won't fix a duff bike under warranty that they sold you...

Which dealer told you that?

[ChainBlueLightning]

SMC in Sheffield. The nearest dealer to me if apparently in Hyde but takes over an hour to drive to. I spoke to him on the phone yesterday and he was very helpful and said it sounds like a corroded connector which would be located under the tank somewhere? is that the one behind the radiator that's been mentioned? I've been trying to google for some images but can only find wiring diagrams and again the bloke in Hyde said if you're using your bike all year round in all weathers and conditions and washing it off even this blasts all the grease off and would probably not be covered by a warranty as its wear and tear.

I havent looked at anything yet. waiting for the weekend so I have some time and some daylight.

my plan is to check out all the different connections at every point if nothing is obvious give em a good clean, ACF50 and a big dollop of grease and go from there.

[UK_Vstrom650]

In which case, the connectors are under the tank, under the air intake box and are located behind/above the radiator. I had issues with these which caused my C41 fault but that was after 3 years all year commuting. There's about 5 connector blocks under there. Clean them up. Pour a good a good measure of ACF50 in all of them,  and I smeared a thick dollop of ACF50 corrosion block on the wires on the back of the  connectors (vaseline will also work). I also did the same to every connector I could get to including removing the tail unit...

Oh, to remove the intake box, the rear is a allen key but the front is a cross headed screw and a pain to reach (I tried for ages to put my allen key in it  ). It might be worth loosening/removing the radiator - probably what I'd do next time.

[Hondaman]

These;

[UK_Vstrom650]

It is crap design on Suzuki's part!!

[Sam]

the bloke in Hyde said if you're using your bike all year round in all weathers and conditions and washing it off even this blasts all the grease off and would probably not be covered by a warranty as its wear and tear.

So he's telling you that using your bike in winter voids the warranty!!