Triumphrat

gregp · 07-16-2008

Lately, over the past week or two, my blue high beam indicator light has started to go on and off without reason. At first, I thought that it was voltage weakness related, as I would turn the key on, the high beam indicator would come on (light switch in low beam position), as well as the oil and neutral lights. I would start the engine, the light would stay on. I would rev the engine and it would go out, and stay out (until the high beam was required, then it would operate normally). But this morning, I noticed that as I would hit bumps in the road, the light would come on and go out erratically. So, I figure that I have a loose connection somewhere, or an intermittant short. Does anybody have any experience with this problem? I am just looking for a hint for where to start looking.
I did just replace my tach bulbs (with stock bulbs) a few weeks ago, so there is a chance that I may have disturbed something while I was poking around in the instrument cluster...
Thank You!
Greg

MickMaguire · 07-18-2008

you really need to start with the switch and its associated wiring - go right back tot he connector in the headlight shell too. Is the actual high beam coming on or is it just the indicator?

gregp · 07-18-2008

Mick, it is just the indicator. The headlight functions normally with the switch, and the indicator comes on and stays on when the high beam is activated. The indicator is flickering on and off randomly when the light is in low beam position. Moving or wiggling the switch does not seem to affect the randomness of the indicator flickering.
Only sometimes does the indicator light come on when I turn the key on.
The total randomness of this problem is telling me that I have a short, a ground, or an open somewhere, and since the last thing I did to the bike was work inside of the tach shell, I suspect the problem lies there.
I will try to dig back in there today (day off of work!) and see if I find anything.
It is "Hot" out today, so I'd rather be riding....
:-)
Greg

ssevy · 07-18-2008

Just thought I'd mention a product called liquid electrical tape that I found at Lowe's. It is especially useful when you have a bare wire or slice mark, but no room to wrap tape, as in a bundle of wires. It dries pretty quickly, and seems pretty flexible once it dires. Also works great for treating the ends of ropes or shoelaces so they don't unravel.

gregp · 07-21-2008

Thanks, Ssevy! I removed my tach bell and re-mounted it. The problem has gone away...for now. I also removed the plastic lens on my idiot lights, to use it as a pattern to build a replacement. I had my daughter following me last weekend and she kept telling me to shut my directionals off! I have had enough of the "dim idiot lights".... and it is time to do something about it. Somebody else here built a replacement lens, and I am going to give it a go as well...

gregp · 07-22-2008

Update: The problem has morphed into something more sinister. I did tinker around a bit inside of my tach bell yesterday, and the problem *seemed* to have been cured, but this morning, as I started up my bike, I noticed that the light was still flinching. I headed off to work, and on my way over the rough road, I noticed that the high beam indicator was staying on. Soon after continuing on, I ended up behind a shiney van. I played with the high/low beam switch and it appeared by the reflection that nothing was happening, but the high beam indicator was still on solidly. As I went a little further, the reflection of my headlight in the van's back doors completely disappeared! Lights out! Well, headlight, at least... my instrument lights were still on, and I could not see my tail light.
When I arrived at work, I quickly checked my headlight operation and all was well. High and Low beam functioned fine at a stand still. So, it appears that I still have an intermittant open or short somewhere, and I will start by replacing the headlight bulb as I have experienced similar problems on other bikes that was caused by a broken filament bouncing around within the bulb. If that does not rectify the problem, I am going to have to start digging.
Greg

MickMaguire · 07-22-2008

you need to be looking inside the headlight shell - my money is on problems with the connectors in there - not the ones inside the tach, speedo or idiot light cluster - but basically tear everythign down and inspect for dirt corrosion or wear.

gregp · 07-22-2008

Will do, Thank You for the direction, Mick!

gregp · 07-22-2008

Tonight, I dove into the headlight shell and found nothing wrong, other than a few corroded pins in some of the connectors. I cleaned them all up as good as I could and sprayed everything down with WD-40. I started the bike up and everything seemed Ok. Only time will tell if I actually solved anything.
While I was playing around in the instrument area, I made up a new idiot light lens with a piece of 1/8" Lexan. Getting the pattern was a bit of a bear, though. I ended up cutting a piece of paper to roughly the size of the lens, then placing it over the back idiot light housing. I then wiped up some road grime off of my alternator and rubbed my dirty finger over the paper, around the edges of the hole. I then cut the pattern out carefully with scissors, and transfered it to the Lexan. I cut the lexan with a band saw and used a Dremel when I got close. You could probably do the whole job with a Dremel if you had the time. I used different colored markers on the back of the Lexan where the appropriate green, blue, and red icons were. It works great! My bulbs had long ago been replaced with LED's and now they shine very brightly. I can almost guarantee that I will not be leaving my directionals on anymore.

MarkBartels · 07-22-2008

You may have already thought of this but it would be a good idea to put some dielectric grease on the connectors....