In the Dark - Lighting problem

[krusty]

1984 FJ1100 resurrection.
Before taking the fairing off to do some work on it and the frame the high beam worked as did the headlight flasher, tail and brake lights. Horn works.
Now that it is all back together I have no headlights at all. Fuel gauge not working either. Tail and brake lights works, indicators work, horn works.
I checked and cleaned connectors while I had it apart.
Before I dive back into it (I hate pulling the fairing off) is there a likely common fault with this model that I'm not familiar with or anything I should pay particular attention to? I have colored wiring diagram for US model.

[aviationfred]

I would first look at your start button. Make sure that it is not sticking. Next I would look in the fuse holder and look at one of the 15 amp fuses. Then i would look at the ground wire from the head light.



Fred

[krusty]

Thanks Fred. I have visually checked them but will try swapping them out.

[ct7088]

If the instrument lamps work there is power to the headlight switch, maybe the bulb died? AviationFred is right only a grounding problem can tie the two problems together. Did the fuel sender connector get pulled apart or not reconnected?

[krusty]

Neutral and indicator dash lights work, H beam dash light does not. Tried another bulb in headlight. Had thought about the ground connections. Methinks I'll be taking fairing off again.

[TexasDave]

Neutral and indicator dash lights work, H beam dash light does not. Tried another bulb in headlight. Had thought about the ground connections. Methinks I'll be taking fairing off again.

Like CT7088 said if your instrument lights work you have power to the high/low switch. Like fred said it is probably a ground problem if you took the fairing off. You should check the Green wire(low beam) and the yellow wire(high beam) coming from the high/low switch to your headlight for voltage. Easily done using one of those cheap auto testers with the light and sharp point that stabs through the insulation on the wires. If you have voltage from the switch it is probably a bad ground. The high beam instrument light is on the same circuit as the highbeam headlamp thats why it doesn't work either. Good luck.  Dave

[Bones]

Check your connector blocks again, I had similar problems when I first pulled my fairing off and refitted it. Connector blocks looked clean but when plugged back in the fuel gauge was reading lower than before and I think one beam wouldn't work.

Make sure everything is clean, spray some contact cleaner in the plugs, and make sure everything works before bolting fairing back on.

                                                                 Tony.

[ribbert]

1984 FJ1100 resurrection.
Before I dive back into it (I hate pulling the fairing off)

Not sure about the early models but on the later ones you can simply remove the bolts (x 4) holding the fairing subframe, about 15 minutes work and without risking damage to the plastic mounting tabs.
The whole thing comes of as one unit, instruments, headlight, everything.

Noel

[Urban_Legend]

I have removed the fairing off my 84 fj about 6 times in the last few weeks (issues with the speedo). Easy job. Lights and dash come out with it. When you have unbolted the fairing (6 bolts holding the fairing onto the frame), wriggle it forward and then you have easier access to unplug the wiring harness and speedo cable. It takes me around 5 minutes to remove and a little longer to replace.

Mark

[Urban_Legend]

Just remembered, if you have the air ducts still on your fairing, these need to be removed first (these are missing from my bike, speeds the process up)

Mark (again)

[krusty]

Thanks for the suggestions. I have had the fairing off for repairs and frame derusting and painting. It was a bit of a hassle trying to get it back on as things didn't seem to align neatly. I think this may because of the bike having fallen over during its long hibernation, hence the broken fairing and duct on the left side which is what needed repair. The fall may have twisted the fairing frame just slightly. As I mentioned in my OP, I just wanted to be aware of any FJ foible that may be the cause of the lighting problem so as I can be aware of it when the fairing comes off. We will be heading over to Mexico in about 10 days so I may not get a chance to fix it before we go but will try if I get a spare moment.
ftp://

[krusty]

Lighting problem is now resolved.
I pulled the fairing today. Just took it off enough to get at the wiring. What did I find you ask? The main wire connection block had not been plugged all the way in. DOH. Gave it another clean, replugged and now we have light. Fuel gauge works too, just needed a bit more fuel in the tank for it to register.
All back together and ready for reg.ftp://

[Bones]

Good job on your fairing fix Krusty.