Is there a fuse in the wiring to the lights?

[rocmoc]

Seems like about 30 years ago I had to change a fuse after a stream dunking in a National Enduro.  But, I don't remember exactly as that was a long time ago.  Lights were working but no front or rear now.  Thanks for any help?  New rebuilt forks are installed and will be a different post after hard ride!

rocmoc n AZ

[rocmoc]

Found my original owners manual with wiring diagram. Does not appear to have a fuse so my nearly 40 year old memory was wrong. What I did find from another source is the magneto circuit for the lights was sized for the running of the front headlight and rear tail-light. If the headlight goes out entirely the circuit will overload the tail-light and burn it out and same for the front. I rode the PE without the headlight mounted on to do a light test of the forks. Maybe that burnt out the tail-light. Will check tomorrow. And the bulbs have to be excellent quality or they will burnout in minutes. Does this sounds like anything anyone else has heard or knows?

Thanks, rocmoc n AZ

[Admin]

. And the bulbs have to be excellent quality or they will burnout in minutes. Does this sounds like anything anyone else has heard or knows?

Thanks, rocmoc n AZ [/quote]
-

That is the problem, the quality of the bulbs and the replacement bulbs specs.
On my bikes, if the brake light has a problem, the headlight remains operational and does not burn out, it is an original Suzuki bulb.
So it is likely the bulbs not being adequate if the rest of your setup is stock.
You can try to find good NOS bulbs at swap meets or perhaps eBay.

It is difficult to find decent 6V bulbs that will stand up to the vibration and impacts of our off-road motorcycles.
First, I think motorcycle bulbs were heavier duty than automobile bulbs and that was always a caution from the motorcycle manufacturers, use a bulb designed for our dirt bikes.
The bulbs sold at most auto stores won't hold up.

[rocmoc]

Yes, rear bulb is blown. I'm going to look into led. Looked on Amazon and they had 6v led with the correct base but need to check further about the diameter. Also the led was only 0.5w while the stock bulb is 5w. Worst thing I "think" could happen is the led blow. Shouldn't hurt the bike's electrical system. I still have to check out the front. Only one beam was working before as one of the pigtails on the bulb is off the back. Will have to open the rubber cover up and take a look. Our monsoon rains look like they are going to start this week so have setup a ride with a buddy after one of the rain storms to test the new forks.

rocmoc n AZ

[Jozel]

I installed a additional rectifier into the head/rear light circuit. Helps to safe the aftermarket bulbs..

[rocmoc]

Thanks I will look into the rectifier. I am going to try a 12v bulb, led and a #81 bulb also.

rocmoc n AZ

[rocmoc]

Front bulb is also burn out. Found a NOS on Ebay and will have it in a week. But I am still going to try the LED route.

rocmoc n AZ

[Admin]

Jul 2, 2021 1:36:30 GMT rocmoc said:

Front bulb is also burn out. Found a NOS on Ebay and will have it in a week. But I am still going to try the LED route.

rocmoc n AZ

-
You can connect an ammeter to the headlight output of the running motorcycle to check the output is not spiking beyond 6V which could cause the blowouts.
Obviously do that before blowing out the new bulb!
A bad ground can cause the bulbs to blowout I believe, so make certain the ground & wires for the lighting harness are clean the ground is good.

[rocmoc]

Problem was/is the same guy has own the PE for nearly 40 years and he (me) never serviced or cleaned the light sockets. Never had to as they always worked. Well the sockets were rusted and one pigtail on the headlight socket was pulled loose from contact with the bulb. Everything is cleaned, a new socket pigtail assembly and new bulb arriving Thursday. Will know by next weekend if it is fixed!

rocmoc n AZ

[Admin]

If the rubber boot over the light socket has become brittle or broken with age, I used one of these HARNESS COVERS cut slightly to the correct length to replace it on mine. Size Medium I THINK but I ordered a couple of different sizes as they come in handy.