XJ 550 Seca and the low beam gremlins - European model

Hello,

Several days ago, the low beam started to switch by itself when taking corners or moving the handle.
After unmounting, cleaning connectors and mounting stuff...several times, I found that when moving with my hand the wires from the left handlebar command (the wires that go under the gas tank) the low beam switches on and off. At the same time the flasher relay goes on and off (a "tic-tac" sound can be heard / felt when holding the hand on it )
Very important! - when moving those wires, while the switch is set on the high beam, this problem cannot be reproduced!

And know the interesting part.
My XJ550 Seca is the european type, and the electrical diagrams found on this forum do not match with what I have on the bike.
1. I have no flasher canceling unit...but this is not a problem.
2. I have no headlight relay ...I know where it should be placed...but there is only the mounting bracket.
3. I have on the right handlebar command unit ...a button (similar with the turn signal button from the left side) having 3 positions (headlight/position light/off) - this, I believe, is the "manual headlight relay" for my bike.

Can you help me find the correct electrical diagram or the root for this problem? Quite a challenge ..eey?
Other info :
The left command has the following wires coming out:
1.brown 2. brown-white 3.dark green 4. Pink 5. Black 6.yellow-red 7.blue-black 8.yellow 9.light green 10. red-yellow
The right command has the following wires coming out:
1.blue-white 2.blue-black 3.blue 4.red-white 5. red-white(again) 6.red-yellow

 

Lately, when I wiggle the cables, coming from the left handlebar command , the headlight fuse dies. Any ideas on this issue?

 

Undo the screws on the bottom of the left switchgear so you can open it up and have a look. I suspect a brake in a wire or worn insulation.

 

does this wire diagram work for you the creator is in Sweden
http://frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html

 

Thanks for trying to help, but when comparing the electrical diagram mentioned above with what I have on the bike it can be seen that:
1. The diagram has the dimmer switch(low/high beam) on the right handlebar command, but on my bike, the dimmer switch is a button that moves parallel with the bike, located on the left command (the same button on my bike , switches between ON/PO/OFF)
2. The diagram has a headlight relay, my bike doesn't have that (by default, no mods were made)

When I want to reach the low beam, I must set the right switch to ON ...and the left switch to Low Beam.

 

Done that, but all seems fine ...I am 99% sure that the problem is somewhere in the bundle of wires, coming from the left handlebar command.
Maybe the green wire is braked, since the high beam works fine, the "blue-black" wire has been excluded.
But how is it possible for the headlight fuse to brake, when I wiggle this bundle of wires? For what reason?

 

If there is a worn spot in the insulation the wire can short to ground, or to another wire drawing too much current and popping the fuse. I think you should take the fuel tank off and have a good examination of your wiring harness and fusebox. Does the bike still have the original fusebox?

 

link to where you can buy wire diagram.
Yamaha XJ550 RH 1980 UK Spec Colour Wiring Diagram

http://kojaycat.co.uk/epages/950000457.sf/en_GB/?ObjectPath=/Shops/950000457/Products/"YAM0145/1"

 

I have a German manual with the wiring diagrams you are looking for.
Start a conversation with me and I will send you a scan of the wiring diagrams.