Headlight/high beam out on 85 FJ

[FJFAST]

Did a search and found a little on this topic but I'm stumped. Headlight and high beam out. Troubleshooting included checking starter switch, and fuses. Finally decided to pull fairing since I needed to repair a cracked piece anyway. The connections look pretty good so I don't think that's the problem. Someone mentioned to check ground but not sure where that is. Did not replace bulb yet..if that's burnt out does high beam still come on?
Help appreciated on steps to take now.

GReg

[Pat Conlon]

Yes, always check the bulb first.

It is very common for the low beam filament to burn out first, simply because that filament has the most hours of use.

Take the bulb out, look closely at the 2 filaments, you should see one broken.

[FJFAST]

Bulb looks ok The bulb connector doesn't look so good.

[Pat Conlon]

Yep, that will do it.....if you do not have a firm positive click connection to the bulb, the terminals in your plastic plug will arc and melt the housing.
Go down to your local auto parts store, look for a ceramic plug (typically sold in pairs) and splice in the new wires. Use a quality crimp connector tool on the female connectors.

http://www.ebay.com/itm/H4-9003-H6054-HEADLIGHT-BULB-CERAMIC-CONNECTOR-SOCKET-PLUG-USA-SELLER-/381027623137?hash=item58b70420e1:g:Vb0AAOSwZjJU78Yc&vxp=mtr

[FJFAST]

So to confirm, if this thing is toast, it would affect the headlight as well as the high beam light? Took the dashboard out of fairing to clean inside (picked up some dust after 32 years of riding it and can't see the trip meter)and checked the high beam bulb...it looks ok.

[Pat Conlon]

Will it fix your problem?

Dunno, but it sure looks like you need a new plug for sure.

Get your multimeter out and check (what's left of) the terminals and see if you have power.

[FJFAST]

Thanks for the link. This unit has three wires but the FJ one has 5..2 black, 2 yellow and a green. So how would the wiring work?

[Pat Conlon]

You have a headlight plug with 5 wires?
Hmmm, I wonder, do you have a "flash to pass" switch on left handlebar switch assembly?
Regardless, the wires are obviously combined because your headlight bulb has only 3 prongs.

Do you have your Owners Handbook?
In the back is a wiring diagram for your model FJ.
If you don't have one, see my signature (below) for the link. Down load one, they are free.
Typically Yamaha uses the color black to identify the ground wires

[FJFAST]

Here's the wiring. I do have a manual.

[4everFJ]

That is the correct wiring.

The headlight plug has 3 connectors and 5 wires. Two yellow goes to one connector, two black goes to one connector and one green to the last connector.

[FJFAST]

i guess I splice the two yellow and two black into the the single corresponding wires on the new connector then, correct. Sorry for seemingly dumb questions but electric stuff is REALLY not my forte.

[4everFJ]

If you duplicate what you've got, you can't really go wrong.. 

[jscgdunn]

One option you might consider is to do the relay mod while you are at it. 

The easiest way:

http://www.easternbeaver.com/Main/Wiring_Kits/H4_Kits/h4_kits.html

I bought one of these kits, and although not cheap there are some real advantages in that you get the small relays instead of the larger automotive ones, and the wiring and connections are first rate.

Or you can do your own and there are some good post on here.

Another thing to think about is replacing the melted connector with a ceramic one (check ebay).  You can then use a higher wattage bulb without worry about meting the replacement.

Jeff

[markmartin]

One option you might consider is to do the relay mod while you are at it. 

The easiest way:

http://www.easternbeaver.com/Main/Wiring_Kits/H4_Kits/h4_kits.html

I bought one of these kits, and although not cheap there are some real advantages in that you get the small relays instead of the larger automotive ones, and the wiring and connections are first rate.

snip

Jeff

+1 on the Eastern Beaver harness and relay. It's easy and your headlight will be brighter.

[FJFAST]

Thanks,
I will check the relays out. The guy at the auto parts store said ceramic plugs can explode if overheated? Anyone ever here of this?

Greg