Reserve Lighting Switch

grumpy56 · 06-28-2009

Any suggestions regarding how to troubleshoot a reserve lighting switch on a 1000J? My "problem" consists of a very dim low beam, the warning light indicating a lighting problem "on", and a high beam warning light that does not function. Tried a new bulb and the shop manual addresses certain scenarios, but not this one. Thanks.

elr658 · 06-28-2009

It needa a 55/60 bulb.

grumpy56 · 06-28-2009

Thanks elr, but put a new 60/55 in it and still have the problem. Does "60/55" or "55/60" make any difference?

Killbert · 06-29-2009

Check the resistance through the ground terminal and the positive terminal. Put one probe in the female spade of the headlight and the other to the corresponding battery terminal. Check resistance. Should be VERY minimal. Seems to me like a bad ground.

grumpy56 · 06-30-2009

Thanks Killbert, but being the novice I am, need a little more help. My headlight bulb has 3 male terminals. Also, would there be some way to ground the circuit so I could tell if there is a grounidng problem? Thanks again.

MFolks · 06-30-2009

The ground circuit wire should be BLACK with a YELLOW stripe. High beam should be a RED with BLACK stripe, and low beam RED with YELLOW stripe.

The ground circuit wire should be the same as the battery negative cable going to the engine mounting bolt electrically.

grumpy56 · 06-30-2009

Thanks Mike. Will check it out.

grumpy56 · 07-03-2009

Checked everything and I believe my reserve lighting uint is shot. When I bypass it, everything seems to work fine. The unit is located on the front of the battery box below the air cleaner. I assume I have to remove the battery box to get to it. Any other suggestions? Thanks.

Killbert · 07-03-2009

Hmm.... It's been a while since I removed and reinstalled my battery box, but I recall having both the voltage regulator and the lighting unit on the battery cage during installation. It's pretty quick to get that sucker in and out. Let us know.

Kellyn

grumpy56 · 07-03-2009

Thanks Kellyn. Found the disassembly seciton in my repair manual and am disconnecting everything. Only thing that bothers me is I hate pulling on 27 year old wires unless I absolutely need to, but what is is!

grumpy56 · 07-09-2009

Update....Replaced the reserve lighting switch and no difference. Pulled the tank tonight and found the problem. Bad 9 pin connector under the tank.

06-28-2009	#1 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Reserve Lighting Switch Any suggestions regarding how to troubleshoot a reserve lighting switch on a 1000J? My "problem" consists of a very dim low beam, the warning light indicating a lighting problem "on", and a high beam warning light that does not function. Tried a new bulb and the shop manual addresses certain scenarios, but not this one. Thanks. __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

06-28-2009	#2 (permalink)
elr658 Eddie Lawson is God! BTK Expert Join Date: Nov 2004 Location: Seymour,CT Posts: 4,645	It needa a 55/60 bulb. __________________ 1982 Kawasaki KZ1000R1 #658 1983 Honda CB1100F Blue. www.myspace.com/79cb750f

06-28-2009	#3 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Thanks elr, but put a new 60/55 in it and still have the problem. Does "60/55" or "55/60" make any difference? __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

06-29-2009	#4 (permalink)
Killbert Riding Vintage BTK Intermediate Join Date: Aug 2008 Posts: 187	Check the resistance through the ground terminal and the positive terminal. Put one probe in the female spade of the headlight and the other to the corresponding battery terminal. Check resistance. Should be VERY minimal. Seems to me like a bad ground. __________________ Riding Vintage.

06-30-2009	#5 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Thanks Killbert, but being the novice I am, need a little more help. My headlight bulb has 3 male terminals. Also, would there be some way to ground the circuit so I could tell if there is a grounidng problem? Thanks again. __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

06-30-2009	#6 (permalink)
MFolks Needs A Real Job BTK Expert Join Date: Jul 2008 Location: Springfield Mo Posts: 3,439	The ground circuit wire should be BLACK with a YELLOW stripe. High beam should be a RED with BLACK stripe, and low beam RED with YELLOW stripe. The ground circuit wire should be the same as the battery negative cable going to the engine mounting bolt electrically. __________________ Mike Folks

06-30-2009	#7 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Thanks Mike. Will check it out. __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

07-03-2009	#8 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Checked everything and I believe my reserve lighting uint is shot. When I bypass it, everything seems to work fine. The unit is located on the front of the battery box below the air cleaner. I assume I have to remove the battery box to get to it. Any other suggestions? Thanks. __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

07-03-2009	#9 (permalink)
Killbert Riding Vintage BTK Intermediate Join Date: Aug 2008 Posts: 187	Hmm.... It's been a while since I removed and reinstalled my battery box, but I recall having both the voltage regulator and the lighting unit on the battery cage during installation. It's pretty quick to get that sucker in and out. Let us know. Kellyn __________________ Riding Vintage.

07-03-2009	#10 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Thanks Kellyn. Found the disassembly seciton in my repair manual and am disconnecting everything. Only thing that bothers me is I hate pulling on 27 year old wires unless I absolutely need to, but what is is! __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

07-09-2009	#11 (permalink)
grumpy56 Turtle Wax Taster BTK Intermediate Join Date: Dec 2008 Location: Yorba Linda, CA Posts: 151	Update....Replaced the reserve lighting switch and no difference. Pulled the tank tonight and found the problem. Bad 9 pin connector under the tank. __________________ Lew 82 KZ1000-J2 06 H-D FXD35 In the past...72 H-D SS350, 72 GT380, 75 Z1B, 77 XLH, 79 CB750K

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