82 Seca Turbo Headlight Warning

The warning center is saying there is an issue with the headlight but high and low beam both work so I'm not sure what the issue is. Does anyone have a good clear wiring diagram for this bike. I have a PDF version but it is not clear enough for me to troubleshoot.

I've tested the headlight bulb and both beams are working. From what I can see from the wiring diagram that I have, the high/low circuits go through the computer so I'm not sure how both beams can be working and it still be reporting an issue There are pigtails on the headlight connector for the high and low circuits but they are not connected to anything but I'm not sure if that is an issue or not.

 

is this a new issue to you?

 

Yes, I just bought the bike and I'm working to get it back on the road.

 

this thread may be of interest to you
New LED Head Light - casuing issues

covers the way the moniter works

are you using H4 bulb or led?

 

Is it a standard H4 halogen bulb or has it been changed?

Is the high beam indicator working?

Does it fail in either high or low beam or both?

Was it working previously and just go bad or did you inherit the issue?

The photo is from a Maxim CMS that also has the pigtails. The Seca does not have them. I can't say for sure if they are connected but they are not shown on the Haynes electrical diagram. I was speculating that they might be needed for fairing additions??



I am still working that LED issue from the thread that XJ550H posted. I have some more answers that I will post later that are related to the high beam indicator bulb, but basically with the stock setup you need to close the reed switch with the active beam, and provide a ground through the filament through the inactive beam to set a safe condition.

 

It does still have the original halogen bulb. I removed the bulb and tested it with a 12v source and both elements work. I inherited this issue so I don't have any history on the problem. Thanks for the article on now the monitor works. I'll pull the dash and make sure the headlight is still running through the computer, maybe someone bypassed it along the way. If not, I will have to assume the monitor is bad.

 

Testing it outside with a 12V source is fine, but both beams have to be functioning in the bike to activate the reed relays. So, does the high and low beam test OK on the bike? If one beam is not working, then the CMS is giving you good information.

 

Yes, both beams work in the bike as well as out. I tested outside of the bike because I was thinking that the bike might have an automatic failover system that will switch the beams if one fails so it might look like both beams are working when in fact it was just failing over. That does not appear to be the case now and both beams are working. I pulled the cluster and the wires are still going through the monitor so I'm thinking there must be an issue inside the monitor? Anyone have a spare I can test with or know where I can get a replacement?

 

A couple of other thoughts to isolate the issue to the CMS:

Check the bulb resistance from HB to ground and LB to ground with a DMM. Should be virtually 0 ohms.

If the bulb checks OK, then reconnect the CMS but remove the headlight relay (or 10 amp head fuse in your case). Doing this will remove the reed relays as part of the picture. Bike should power up with no fails.

Check the floating voltage at the headlight connector with it disconnected. LB should be 12V, and HB should be 4.2 volts with the headlight fuse installed and the CMS active, or both at 4.2V with the headlight fuse removed or the CMS not enabled.



Edit: Changed CMS active for floating voltage check and added bulb diagram

 

.3 and .6 ohms on the bulb.

With the fuse out I see .1 vdc on the leg I have the hi/lo switch set for and 0 on the other leg. This flips with the switch.

With the fuse in I see 12vdc on the leg the switch is set for and 0 on the other leg, also flips with the switch.

With the fuse out the bike powers up but the warning is still there.

 

All of this testing was done with the CMS connected but the bulb out of the socket.

 

With the bulb in I am seeing ~9.8v on the active leg and .5v on the passive leg.

 

I was just about to ask that question about the bulb.

I could have been clearer on this. This should be done with the fuse removed and the headlight plugged in to provide filament checks. It looks like you are still going to get the fail though as there is no monitoring voltage present for the headlight with the headlight plug removed.

I have to speculate here as the part numbers are different for the Turbo CMS CCA:

5G2-W8352-00-00 Seca 1981, 1982, 1983; 15R-W8352-00-00 Maxim 1982 Only; 10M-W8352-00-00 Turbo 1982, 1983

However, even with the different part numbers it would make sense that a filament monitoring voltage would have to be present and measurable with the headlight bulb disconnected. I know we have some other Turbo members on here, so it would be nice if one of them could weigh in on what they see as floating voltages with the headlight unplugged and the headlight fuse removed.

Not sure you want to go there yet or have looked but there are 4 available on Ebay for a reasonable price.