Boxerworks.com

Hello!

R80 bitsa here (wiring mostly fits 1981-84 description according to moto-bins). Last season i had a meltdown in the headlight wiring when a short occured from the main bulb socket. The harness from the left hand switch melted, as did the wiring to the socket, and also one of the red wires to the starter relay. I have now replaced the switch/wiring assembly, replaced the headlight relay, and the headlight wiring. The red wire to the starter relay (thin one) is also replaced (goes with fat one on same spade connector in relay).

Now I can use the hi/lo switch again, indicators work, rear light/brake light works and horn works.

On the downside I have no instrument lights, no charge warning light, no oil pressure warning light, no high beam warning light and no side flash warning ligt. Neutral warning light works.

Charge is indicated as 11-ish on voltmeter when cruising, measured on the battery with multimeter 11.95 volts.

Before I had plenty of charge risng with revs to 13,5 volts. Charge regulator was new when meltdown happened.

Can anybody point me in the right direction as to a cause and a cure?

Cheers from Otto in Denmark

The current that passes through your charge indicator light is needed for the charge system to function correctly, so, while I can't tell you exactly where your dash light problem is, it is quite possible that a single solution will fix both the instrument lights, and the charge system.

Many bikes have a neutral switch which grounds out the line to light the neutral switch, while the other warning lights ground through the same instrument cluster ground. A bad (or missing) ground is the first place I'd look.

Edit: BUT, I don't think that would kill the charge indicator light, so I take it all back - look at the schematic and try to find a power lead that feeds all those systems. Either way, it has to be a wire that is connected to all those different items, so, with a schematic, it shouldn't be that terribly hard to find.

I had a similar experience, being color blind, I could not tell the differnce between the red and brown wires. Got the wires wrong on the bulb socket and fried the wiring harness and the switch. Did you replace the switch? The contact on the switch will melt away and, of course, no longer make a connection.

Thanks folks!

I have replaced all the bulbs, but found some still didn't work. The Charge light worked again, and made for a healthy charge - relief! It turned out that the remaining bulbs (hi/lo indicator and turn indicator) didn't work due to bad connections to the printed circuit. These were restored with some wiggling and folding back of the copper foil. Now everything is dandy! I have even replaced the seat cover and centre stand bolt, so in fact there is nothing left that's the least bit iffy - maybe except for the worn piston rings...

Otto in Denmark