I'm at work and don't have my diagrams to pull out and trace, so I thought I'd post it here - someone might be able to jump on this and help him out before I get the chance:
I have been searching through the web site looking for any information that might help me with a major electrical issue I am having with my 96SE. Below is a response you made in an old message from 2012.WingAdmin wrote:The power for the headlight goes to the switch, which then splits it to send it on one of two routes - low and high beam, each with a separate wire. Normally the failure point is the switch, but if you have an aftermarket added DPDT switch for passing lights, that would be the first place I'd look.
Currently I have a headlight issue (as in no lights). The bulbs are good and I can directly wire them and confirm this. I have been thru all the “standard” fixes trying to resolve this issue, including checking and validating the relays, checking fuses, I have dismantled both the hand controls, cleaning both the hi/low beams switch and the start switch. After all of this I believe I have tracked down “the reason” for my issue, but it raises a bigger issue. The previous owner had a pair of halogen fog lights mounted on the front of the bike and during the course of my investigation; I have tracked the issue to this wiring. It looked like he tried to do the right thing by using a relay under the right hand fairing pocket. This relay had a power source directly off the + terminal (fused), a trigger by tapping into the BROWN wire feeding the light on the side of the fairing, a wire spliced in to the GREEN wire on the same light for the ground, and a split lead going to each of the lights. Pretty straight forward. What makes absolutely no sense is the BROWN wire (+12VDC) had a splice. I traced this wire and found a wire going into the LH controls had been cut, and this (+12VDC) power was connected to the BLUE/White wire going to the Hi/Low beam switch. I have scratched my head trying to understand the reasoning for this but just cannot come up with anything solid. Only thing that I can come up was if there was a problem somewhere along the wiring for the reverse system that was preventing power being sent along this wire, he took it upon himself to “bypass” the issue and supply power directly to this circuit. When I got the bike, one of the headlamps was out, so I got some new H4 Sylvania bulbs. Based on your statement above, I am guessing this BLUE/White wire (L/W in my Clymer manual schematic) is the power source for the lights. These new bulbs (along with both operational) were overloading the aux light circuit, and causing my fuse (15amp) to blow (I believe this was fuse #8 but I am going from memory). Right now I have removed the driving lights and removed all of the wiring associated with them. After replacing the fuse, everything works except the headlights. I have tried “reconnecting” the BLUE/White wire where it was severed, but there is no power on any of the3 wires feeding Hi/Low beam switch. Right now I am extremely frustrated and frankly running out of ideas where to look. To be honest I am about ready to run a purely manual switch and new relay for the headlights and remove them from the factory harness. Can you offer any suggestions? I have tried to follow the wiring diagrams but I cannot confirm where the power feeding the Hi/Low beam switch comes from. If it is the BLUE/White wire, then the only option I see is to try and trace it from connector to connector look for another break somewhere. The only other thing I can confirm is the reverse function is not working correctly. When I took delivery, the first thing I did was do a baseline maint (oil, filters, ect) and had removed the reverse handle and figured I had something out of adjustment. Since this BLUE/White wire is routed thru several reverse control devices, could it be possible something in the reverse circuit is preventing the +12VDC from being sent to the BLUE/White wire?
I have never had a bike issue like this cause me so many headaches and I am really starting to get discouraged. In the old west, I would be contemplating putting the old girl out of here misery, but I haven’t had the pleasure of a good trip on her yet. These things cannot be THAT difficult can they? I apologize for ranting on, but you seem like the kind of person who really understands the wiring on these beasts and since the explanation was so long winded, thought a PM might be a better way to start than to post a message. If you think a new post would be a better approach, I can go that route, but being a new guy, I do not have a comfort level with all of the major players. Based on my research, I believe both you and virgilmobile seem to be the most knowledgeable on the electrical troubleshooting. Again, I really appreciate all that you are doing with the site and could not have gotten as far along as I have without it. Just now I’ve hit a roadblock and not sure exactly where to look next. Any help or suggestions would be greatly appreciated. Again I apologize for being long winded.