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Headlight/high beam out on 85 FJ

Started by FJFAST, April 30, 2016, 02:58:32 PM

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FJmonkey

The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

FJFAST

Thanks guys..getting there..I think..

FJFAST

Ok..so I think I have the kit hooked up right..followed EB instructions. Connected the harness to the battery nothing. Plugged in the dash connectors and no highbeam indicator either. Attached is a pic of my connection.
Any ideas?

Greg

Pat Conlon

That black wire is a ground. You need a ground to the EB relays for them to work
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

FJmonkey

Going back through the earlier posts on this thread I think you missed one very important step. Solving the original problem of no power to the lamp plug. The two relays in the EB kit need this power to know when to switch on and off (no power, they stay off). The original lamp connector looked quite toasted. You may have a burnt/broken wire that is no longer conductive. Electrical trouble shooting in a wire harness can be a real pain. The good news is your problem is not intermittent, the hardest to solve. You have 100% failure, so once you find it you will know. Use your manual, to help trace the wires based on knowing what colors they are. Use a multi-meter and verify that each of the wires for the lamp connector have continuity from the connector to where they connect on the other end. A good place to start is the fuses. Pull each fuse one at a time and measure for voltage on each side of the fuse holder. If all fuse positions have power then work from the fuse towards the lamp connector.
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

ct7088

Check the bulb, did this problem start with no high beam?
The twisted together yellow wires do they go far enough to make contact inside that blue connector?
the high beam indicator should be on if there is power to the yellow wire even without the relay connected

Chris
Chris

FJFAST

Quote from: ct7088 on May 22, 2016, 04:50:54 PM
Check the bulb, did this problem start with no high beam?
The twisted together yellow wires do they go far enough to make contact inside that blue connector?
the high beam indicator should be on if there is power to the yellow wire even without the relay connected

Chris

Guys..

EB instructions say to cut and tape old ground wire.
Bulb good..tried a couple
I guess since it's a direct shot to the bulb it would fire.the bulb on my circuit tester is shot.

FJFAST

Fjmonkey...one step at a time I guess. Will need to get new tester bulb.

a.graham52

You really should use some heat shrink but splices to reduce the chance of corrosion in them bare wires

FJmonkey

Go easy on Greg, he needs to get it working first. Then he can feel comfortable cleaning up the wiring. Like he said, "One step at a time". I agree, One F%$# thing at a time like my favorite boss always said. We are all here being helpful, keep up the the support.... :good2: 
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

FJFAST

I did buy heat shrink but it was too small...that was temp to see what's going on. Hate this electric stuff.

Derek Young

I had a problem years ago with my '86 high beam while running a 55/100 bulb. I must have been running it all day on high beam and it overheated the high beam/low beam switch. The solder attaching the high beam wire to the switch let go and no high beam. The low beam worked fine. It was an easy fix once I found the problem, just cleaned it up and re-soldered it. Check that out. Take apart the left side handlebar switch.

Derek
1986 FJ1200 (R.I.P.)
1991 FJ1200
Nanaimo, British Columbia

FJFAST

Ok guys..finally diving into it. What I have so far
1. Have voltage off of R/Y at starter switch
2. Have voltage at L/B (which manual says is blue/red but I have a blue/black)
3.no voltage off of dimmer switch (blue/black, yellow,green. Solder looks good. I guess I should have some juice out of these? Bad switch?

ct7088

Red with yellow stripe wire from headlamp fuse goes to the starter switch. The starter switch cuts power to the headlamp when starter is engaged. The blue with yellow stripe wire (power wire) then is routed to the dimmer switch. There is also a solid blue wire connected to the blue with yellow stripe wire, the diagram doesn't show where. The blue wire powers the meter illumination(instrument panel lighting). Looks like the starter switch would be the primary suspect. While it can be cleaned with contact cleaner it needs some lubrication for protection from corrosion and friction.

Chris
Chris

FJFAST

How do I tell if there is a bad ground?