Neutral Switch? Headlight wires

[Red_Hen]

Hi Guys,

As I'm working up to starting the R65 wondering if one  of you will tell me if there is a sensor wired to the clutch handle?  With the bike in neutral, when I push the starter switch nothing.

When I pull in the clutch it engages.  Any suggestions?

Also, I checked my headlight bulb - it tests okay on the multi meter.  The smaller bulb I replaced - it was dead.

Is there someplace on the harness I should check as to why the low beam doesn't come on when I turn on the main part of the ignition in the start position?  The high beam switch works but no lo beam.

Trying to resolve all the electrical stuff before firing her up.

[Bob_Roller]

There is an interlock switch on the clutch lever, there should be a small wiring harness going to the front of the clutch lever area .

Does your neutral light indication on the tachometer work, they work together, so you don't engage the starter with the bike in gear, without the clutch lever pulled in .

Your going to have to check the wiring from the head light switch to the connector at the head light lamp .

Should be a solid green wire from the switch to the head light connector in the head light housing .

Correction on the wire color, it's yellow, got my color abbreviations wrong last night GE is yellow gelb in German, GN is green .

From the wiring diagram, there is only one connector between the switch and head light .

[Rob Valdez 79 R65]

Here is a good shot of the switch body from the bottom.  Just follow the red arrow (pointing to the well-greased cable barrel).  It will lead you to it:





There is also a neutral interlock switch on the bottom of the transmission.
It can only be accessed by -
1) removing the transmission
2) sliding the transmission backward
3) removing the rear engine mount stud, and removing the large metal spacer that goes across the back of the engine.

All three are a PIA.

I would rather slide the transmission back than remove the spacer.  The spacer is a tight fit.

[Mike V]

Ken,

Here's a simplified lighting diagram for my 81 650.  Hopefully this will help if your application is similar.

[Red_Hen]

Good stuff as usual - thanks, guys!

[Rob Valdez 79 R65]

Do you mind if I add that diagram to my online collection, Mike?

[Mike V]

Not at all Rob, you're welcome to it.


Thanks! ~R

[Red_Hen]

I'm wondering .  .  . if the headlight relay was INOP would that prevent the headlight circuit from working?  Would a blown fuse prevent the circuit from working?

On the fuse note, I'd like to replace original fuses with new ones - do they have to be the same kind?  How many amps does the fuse need to be?

Mike - nice diagram - I'm hoping someone will teach me how to read it someday - I'll print it off and ask Matthew Parkhouse if he'll explain.  He will be selling airhead "stuff" at the rally.  He also said he'd be doing some classes on how to troubleshoot electrical problems on airheads - I'm in on that one!

[Red_Hen]

Good Morning,

Headlight:  I used my VM to do a continuity test - there is a good connection between the yellow headlight wire to the wiring harness where the headlight relay fits into.  I also hear a beep when I halfway put in the relay and touch the lead on the post.  But is there a way to test the relay?  How do I know if it's working as it should?  

Neutral Switch:  Is there polarity on the neutral switch connection under the transmission?  If so, I may have the wires reversed - I see the diagram Rob posted but don't see where there is a switch in the handle - do I need to take it apart?

Thanks guys,

Ken

[Bob_Roller]

The neutral switch doesn't care which wires are on which terminal, you have two wires, one has voltage all the time, the other is a ground, the switch just completes the circuit when the transmission is in neutral, and is 'open' when the transmission is in anything other than neutral .

[Red_Hen]

Bob - is there a way to test the headlight relay to know if it's working?  It seems a lot more sealed than the other relays - I wasn't able to pull off the cover & don't want to force it.

[Bob_Roller]

If your high beam works, the relay is not at fault, it shuts off if I'm not mistaken, all of the lighting when it activates  .

If you can get to the yellow wire the handlebar light switch, you can check for voltage as it comes out of the switch body itself I think there  may be a solder joint there, if you have voltage there, you need to check the wiring out to the connector at the headlight itself .

If there isn't a solder joint visible at the switch, you need to follow the wires down to the connector, then check the wire at the connector, don't separate the connector, you'll lose the power going to the switch, get the multimeter lead into the back of the connector and touch the metal terminal end .

[Red_Hen]

I'll do that and report back my findings - thanks, Bob