headlight issues

Hi all, I have a 1982 XJ750 Maxim. I have a problem with the headlight.
My headlight doesn't turn on anymore and it happened out of nowhere (as most problems do).
The rest of the electronics are fine. All lights on the instrument cluster work and the bike runs fine. I also even checked the wiring connections with the bulb from the headlight. (see my small story/rant below) The rest of my bike mechanically is stock and in great condition.

I have already checked the bulb, the fuse and have a new battery in the bike. The previous owner had messed with the wiring and changed all but one fuse to inline fuses which had already been checked and are fine. He also took off all of the original lights front and rear (headlight, taillight, turn signals). I have a circular headlight on the bike and an LED taillight that the original owner installed and that was it.

I had issues with the high beam where it wouldn't work and just the low beam worked (it was a result of my buddy and I messing with the wiring when I first got the bike in an attempt to add turn signals to the bike with limited knowledge on wiring and the bike). That has been a non-problem issue in the year I have had the bike. I disconnected to wire for the high beam to the bulb due to the highbeam issue last year when the wiring mishap occurred. When I switched to the high beam the light turned off (since the bighbeam light was disconnected) but the instrument cluster light still turned on every time. (My buddy switched the ground and the high beam cables by accident which burned out the high beam and the bulb connector one of the very next times I used the bike at night. I had the splice the cables to add a new bulb connector onto the bike which only led to the low beam working since the headlight was slightly melted but the low beam continued to function normally for the next year up until now)

When I tested the new bulb it worked about two or three times. I turned the bike on and off to test the new bulb when it worked to see if it turned on when the bike was turned on. I also flipped the switch from low beam to high beam during those two or three times to double check if it worked. Now the headlight won't work at all.

Any ideas on what else I can do to try and fix the issue?

As a side note I did notice the petcock on my bike is leaking slightly, (which I have looked up on how to fix/repair or to replace and feel comfortable doing that) is there any way this also may have contributed to the problem and shorted out the headlight even though the rest of the bike is functioning fine?

The thing that is unfortunate is that I work 7 days a week and live in a city where I have to keep the bike on the street. Thus my daylight and work space is extremely limited. In addition to that I am limited to small toolbox of tools to work on the bike in addition to limited funds to pay for bills for myself and for my wife etc. I am also still relatively new to motorcycles since I have only had my Xj750 (which is my first bike) for a little over a year now and have little/limited knowledge on motorcycles/electronics wiring.

I was searching the site and found a thread that included about buying and installing a new headlight harness that only took about 90 minutes to do. I couldn't find the thread after trying to look for it again in case it could have been an issue with a bad wire. I was wondering if anyone knows of the thread I was referring to in addition to others things I could do to fix the issue.

 

It sounds like there is quite a bit wrong with the wiring. the headlight isn't supposed to come on at all until the engine starts (I'm assuming that by the bike being on you are talking about the ignition switch being set to 'run' and not the engine having started. If I'm wrong about that assumption, please let me know).

 

Normally with my xj750 the headlight turns on once I put the key in and turn to run before the bike is started. Now this have been due to the previous owner changing the wiring. Since I have owned it the light is on before I start the bike. Now it is not.

I don't know what my next steps would be to find where to problem lies.

 

I had a little bit more time on my hands today during work and came across a thread about the headlight relay possibly being an issue. Part of the thread states that you can take the relay out and clean it. What materials would be appropriate to do so?

 

I use a small 'jeweler's' file and emery paper for cleaning my electronic connections. Then slather with die -electric grease.

Most use the grease sparingly, I am generous with the grease because I lost a 8oz tube of the stuff, bought a new tube and then of course preceded to find said lost tube.... now have die-electric grease for generations to come!

 

You will not find a headlight relay on the Maxim. It utilizes a combination starter / headlight switch that has a set of normally closed contacts for the headlight. When you push the start button the normally closed contact open and the headlight turns off.

As for no headlight now you need to do some continuity checks and inspection to find out why it is not working. Sounds like you have some wire cleanup to do also if the H4 plug has been melted from being wired incorrectly. The failure could be anywhere from the normally closed contacts on the starter switch needing to be inspected / cleaned or the high / low switch not working or the wiring in between.

Do you still have the CMS (Atari)?

Does the high beam indicator light still come on?

 

I do have the CMS. The headlight indicator light doesn’t come on.

Even when it was just the low beam working and the switch was flipped for high beam, the high beam indicator still came on.

 

Update: I ended up fixing the spade connectors from the headlight connector that connects to the original wiring harness. Used an extra bulb that I had from a new headlight that I have yet to install and the headlight now works. I was even able to get my high beam back.

 

Sorry, I missed that you have a Maxim.

 

The 650 maxim headlight comes on after the bike fires, but I know my 1983 750 maxim headlight comes on when the key is turned on...