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Headlight/fog light wont come on. Help

Discussion in 'XJ Technical Chat' started by Ass.Fault, Nov 2, 2009.

  1. Ass.Fault

    Ass.Fault Active Member

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    I have an issue, no light from the headlight(low or high) or fog light.
    Fusebox is new, power to both sides of the box.
    There is current flowing into the yellow wire of the headlight connector(grounded into the turn signal ground), but I am only using a test light.
    H4 headlight is brand spanking new too!

    My question: Is there any great points to start looking? A plastic connector, or busted relay.
    I intend to trace the harness fully, but will need to get aquainted with the confusing wiring diagram more :roll:

    PS I am not a electrical expert, I have very limited knowledge/experience.
     
  2. Robert

    Robert Active Member

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    Howdy,
    Since both lights share the Headlight Relay, I'd start there. You should see 12V at the Red/Yellow wire going into the relay. The relay, when energized should pass 12V along to the lights through the Blue/Black wire (this wire passes along through the headlight high/low and foglight switch). If you don't see the voltage passing through the relay, make sure the relay is seeing the correct voltage to actuate it. If not, your supply from the diode bank or ground could be bad.
    The headlight issues could be as simple as a blown fuse... Check the fuse in the headlight bucket (should be 5A).
    As for the fog light (or auxiliary low beam) it is supplied voltage through the foglight switch which in turn is supplied by the headlight relay.
    In either case, you should clean out the relay contacts
     
  3. parts

    parts Member

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    my headlight went out and it was the start switch.
    the blue/black headlight wire was just a little bare and
    shorted out-worse yet it melted the inside back part of
    the switch and it would stick and not come back out.
    i ended up running a inline ten amp fuse (one for headlamp and one for highbeam) from the batt to
    the head light and a dbl poll single throw switch to the middle
    of the handle bars and another switch super glued under the start switch.
    it all looks and works great and i can keep the lights off when warming up the bike.
     
  4. Ass.Fault

    Ass.Fault Active Member

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    **UPDATE**
    I started off by testing the headlight relay. I didn't have a multi meter available to me so I did the next best thing. I removed the headlight relay and replaced it with the safety relay.
    Turn the key...LET THERE BE LIGHT!!

    I the performed a visual inspection of the headlight relay and low and behold I discover unclean terminals.
    I grabbed hold of the isopropyl alcohol and a couple q-tips.
    Soon the copper color is shining brightly :)
    I then apply some dielectric grease and plug the headlight relay back in.

    After a couple tests I have confirmed the relay is back on its duties.

    I plan on upgrading the relay to a standard relay with an OFF switch, and soon to come an HID upgrade/new headlight housing. More to come as I get bored.

    Thanks for the help guys, it is much appreciated.
     
  5. scubadvr273m

    scubadvr273m New Member

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    Sorry to ressurect a dead thread but I am having the same issue with my 82 xj750. The reason I bring this beast back to life is because the wire colors on my headlight relay do not match what is in the service manual or in any thread I have seen here. First I am assuming that the headlight relay is the rubber coated one on the left directly under the fuel tank and not the metal one on the right. If that assumption is correct the the wire colors going into my relay are as follows;

    Brown, Black, Yellow/Green stripe, White/Green stripe, White/Red stripe, and Yellow/Red stripe.

    Am I looking at the wrong relay or do I not know what year/model my bike is? HELP!!!! I really NEED to get out and ride but refuse to ride w/o headlights. TIA
     
  6. scubadvr273m

    scubadvr273m New Member

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    Hey thanks for all the replies, I've come to learn that this particular forum is always underwhelming in the assistance provided. Figured it out myself, the relay somebody on this forum told me was the headlight relay wasn't. Of course my rusty troubleshooting skills always can use the dusting off. Thanks again!
     

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