Headlight not working - Police bike

[mjh]

I am riding a 1988 Kz1000 Police bike. It is used in funeral escorts. I would like some information on the headlight circuit. I cannot get the headlight to work in either high or low beam. I've checked fuses that I can see and all are ok. Checked bulb, it's ok. Checked continuity from headlight socket to fairing, fairing connector to other connectors. Ground continuity checks ok. Left and Right signals ok. Emergency flashers ok. Pursuit lights flash ok. It has been used by some police agencies in the past and the wiring under the seat is like a bowl of spaghetti made by twelve different chefs.
There is a fuse block with several fuses located directly behind the battery. The fuses are ok. There is also a fuse block with two fuses mounted in a closesable box mounted under the left side panel.
Someone mentioned that some Kawasaki's must be running and then the headlight will work. Checked that - no luck.
What have I missed. Is there a separate circuit for the headlight?
Any help would be appreciated.
Worst case is I do a bypass switch for the headlight high and low beams.
Thanks for your help.
mjh

[StarGate]

Worst thing about those police models is they always get rewired by the police and any escort services that buy them next. With all the diff gadgets that get attached and removed it's almost always in need of a rewire job. Did you check to see if there was power to the Hi/Lo beam switch?

[bountyhunter]

Originally Posted by mjh

What have I missed. Is there a separate circuit for the headlight?
Any help would be appreciated.

Strictly a guess, but is it possible they had some kind of flasher circuit added to the cop versions to make the headlight blink high-low when the activated the lights and sirens?

I wonder if you can get an accurate wiring diagram for that model from kawasaki.

[Kawa 1982]

that there are three wires connected to the headlight. The Black / Yellow wire is the ground. The Red / Yellow wire is the Low Beam side it runs to the Dimmer Switch. The Red / Black wire is the High beam side. It runs to the high beam side of the Dimmer Switch. The Blue / Yellow wire on the dimmer switch goes through the starter lockout switch to the On position of the Lighting Switch. There are three wires to the lighting switch, L, R/L, and L/Y. The L (blue) wire (12V Power) goes to a 10A fuse in the fuse block under the seat. The R/L, Red / Blue wire goes to the Illumination Lights and the Speedometer Lights. The lighting switch appears to be a three way switch. With an On position (L and L/Y are connected) an Off position (L and R/L are connected and finally a neutral position.

Based on my limited knowledge and the assumption that your headlight is good and also that you already found that the fuses under the seat are good I would start with the Lighting Switch to determine that the Blue wire has 12V. I would then check to be sure the switch is transferring power to the Blue / Yellow wire if it is then the next step is the Starter Lockout Switch. Then to the dimmer switch. I suggest that you clean all of the connectors with contact cleaner and then apply di-electric grease to the connectors while you are tracing the problem. Good luck. The wireing diagram that I am looking at is for the 1982-2002 KZ1000 Police P1 & P21. Clymer M451-3 manual.

[mjh]

Originally Posted by Kawa 1982

that there are three wires connected to the headlight. The Black / Yellow wire is the ground. The Red / Yellow wire is the Low Beam side it runs to the Dimmer Switch. The Red / Black wire is the High beam side. It runs to the high beam side of the Dimmer Switch. The Blue / Yellow wire on the dimmer switch goes through the starter lockout switch to the On position of the Lighting Switch. There are three wires to the lighting switch, L, R/L, and L/Y. The L (blue) wire (12V Power) goes to a 10A fuse in the fuse block under the seat. The R/L, Red / Blue wire goes to the Illumination Lights and the Speedometer Lights. The lighting switch appears to be a three way switch. With an On position (L and L/Y are connected) an Off position (L and R/L are connected and finally a neutral position.

Based on my limited knowledge and the assumption that your headlight is good and also that you already found that the fuses under the seat are good I would start with the Lighting Switch to determine that the Blue wire has 12V. I would then check to be sure the switch is transferring power to the Blue / Yellow wire if it is then the next step is the Starter Lockout Switch. Then to the dimmer switch. I suggest that you clean all of the connectors with contact cleaner and then apply di-electric grease to the connectors while you are tracing the problem. Good luck. The wireing diagram that I am looking at is for the 1982-2002 KZ1000 Police P1 & P21. Clymer M451-3 manual.

Kawa 1982:
Thanks, that will help. Where would I find the Lighting Switch. Is that in the ingnition, (key) switch? Also, where is the starter lockout switch?
Yes, the bulb is ok. I can make it light by itself with 12 volts.
Thanks for your help.
mjh

[Kawa 1982]

The starter lockout switch is located on the clutch lever. I am assuming yours is like my KZ1100 A2. I have to depress the clutch lever to start the bike. The previously referenced L/Y wire passes through the connector for this switch. The switch when released, (clutch lever depressed), makes a connection with two black wires in the switch enabling the ground.

The location of the Lighting Switch has me stumped. On the wireing diagram for your bike it is shown in close proximity of the Pursuit Switch, Stop Switch, and the Starter Switch. All of these switches are connected to a plug in type of connector with eight wires going through it. The Blue, Red/Blue, and Blue/Yellow wires connect to the lighting switch. The Red/White and Green/White wires connect to the Pursuit Switch. The Yellow/Red wire connects to the Stop switch. There is a Red wire that goes to the Starter Switch and then to the back of the Stop Switch. That should be a total of eight wires. I would look for this connector inside of the headlight bucket.

Once again Good Luck.

[mjh]

kawa 1982:
Hey thanks for the info on the switches and wiring. I will check them out. I know I have several non-motorcycle projects and things to get done so it may be quite a few days before I get back to the kawasaki, but I will get you an update when I get it traced out.
thanks for your help.
ride safe and keep the shiney side up.
mjh