I solved my intermittent headlight problem

[T Legg]

I have had an intermittent headlight problem. It first happened to me last september .After checking the fuse it began working again when I started the bike. It happened breifly a few more times after that. I checked all of the wiring connections but couldn't find a problem.Tonight it had me stranded miles from home on a night with no moon. Luckily I had a flashlight and my owners manual with me.  Even though I didn't have a meter the symptoms of the tail light working but the head light and instrument lights not working pointed to the starter switch. I found it was sticky and did not return fully to the off position after being depressed to start the bike. I pushed the start switch back to the full off position and once again had a working headlight . It's something to check if you find yourself in the same situation. I will take apart and clean my starter switch this weekend.

[Motofun]

There's a weak spring under the start switch.  It's subject to rust and then failure.  I've had 2 go bad over the years.  i usually find it when the starter refuses to disengage after starting the bike.

[Charlie-brm]

Me too, the starter kept running. It was my first week with the FJ and I had no clue what was going on. Unfamiliar bike so unfamiliar sounds to learn with time. So here is a whining sound I thought might have been the engine going south or not getting oil. 90 minutes from home at the end of the day but still too light out to notice if the headlight was working. I wouldn't have thought of that anyway.

I was sure I had an engine problem until I put two and two together while I was shutting down and restarting the bike a few times and the issue went away with all of that button stabbing. Damn, I don't have the fortitude anymore for shit like that happening to me.

[Mike Ramos]

I have had an intermittent headlight problem. It first happened to me last september .After checking the fuse it began working again when I started the bike. It happened breifly a few more times after that. I checked all of the wiring connections but couldn't find a problem.Tonight it had me stranded miles from home on a night with no moon. Luckily I had a flashlight and my owners manual with me.  Even though I didn't have a meter the symptoms of the tail light working but the head light and instrument lights not working pointed to the starter switch. I found it was sticky and did not return fully to the off position after being depressed to start the bike. I pushed the start switch back to the full off position and once again had a working headlight . It's something to check if you find yourself in the same situation. I will take apart and clean my starter switch this weekend.

Howdy Travis!

Re: unusual electrical symptoms... while not at night, it was in the early morning, cold & raining quite hard.

After a run from the Bay Area heading north, I stopped at the last fuel stop before home with an hour to go.  When I pushed the start button there was no response.  However the red fuel and low level lights did energize.  Initially I thought the emergency ignition switch had been inadvertently turned off but it was in the run position.

Both the side stand and clutch switch wires looked okay.  Curiously, the neutral light was off although the transmission was in neutral & this turned out to be the main factor in determining the problem.

Eventually I began checking the wiring under the carbs and behind the heat shield.  Although difficult to see, I did pull those wires I could reach to ensure they remained connected.  As I pulled, I heard a solenoid click on & the neutral light came on.  Everything returned to normal and I made it home without additional problems.

To properly access the wiring in that location, the carbs need to be removed.  There are four, two prong connectors.  The connector with a light blue wire and a red (& brown?) wire was the culprit – one of the wires was brittle where it entered the plug.  Strangely enough, as I was checking the other wires, the ones that go to the side stand switch broke clean where they enter the connector!
 
Another item to check – preferably when at home in the shop & not out on the road...!

Ride safe,

Midget

P.S. memo: although it was raining; the radar detector, remained powered up, & functional, throughout the ordeal...!

[Sparky84]

P.S. memo: although it was raining; the radar detector, remained powered up, & functional, throughout the ordeal...!

and which weatherproof radar detector, would that, be MR?

I pushed the start switch back to the full off position and once again had a working headlight . It's something to check if you find yourself in the same situation. I will take apart and clean my starter switch this weekend.

I use a bit of silicone spray on the plastics to the sides of the button to assist it to spring back.
Maybe I should also find another spring

[T Legg]

All these stories are why carrying your owners manual with the wiring diagram is even more important than carrying an electrical meter (although I never go on a long trip without a meter).

[Miker]

Same happened to me. I took the switch apart and made a new spring with .725mm piano wire. No problems since. If you do take the switch apart be careful not to lose the loose single ball bearing under the tension spring. Though, it's the same size as a standard size bb in case you do lose it.