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Discussion Starter #1
Sorry, this is a long post but I wanted to list everything I’ve checked so far.

I have a 2006 V-Star 650 that headlight doesn’t work and I’ve tried checked just about everything. I have an electrical engineering degree so debugging electrical issues is usually pretty easy for me. The problem is the circuit diagram in the PDF service manual floating around is outdated/incomplete and also things become very difficult to trace once a wire goes into a bundled wiring harness.

  • Bike is completely stock as far as I can tell. No aftermarket lighting
  • all other lighting is working fine; didn’t notice any check engine lights when i started it last
  • with the key in the ‘On’ position, engine still off, headlight remains off in either dimmer switch position
  • Bulb has continuity
  • Headlight fuse has continuity and also +12V on both sides of the socket. I also tried swapping in a spare fuse
  • No voltage at the bulb socket. One of the 3 socket wires has continuity to ground/negative
  • No voltage on any 3 of the contacts on the handlebar dimmer switch
  • Dimmer switch is working correctly. I tested for continuity in both positions at the harness connector
  • No voltage on any of the 3 wires for the dimmer switch on the connector for the handlebar controls (measured on bike side connector)
  • Blue/Black wire on that connector probably leads to a white relay mounted behind the battery box. Replaced this relay with no effect
  • White relay has 4 wires: (2) red/yellow, (1) blue/black, (1) white/black
  • white/black wire goes to the computer that is behind the plastic panel in the battery box (ignition module I think, looks like eBay link below)
  • Blue/black goes to dimmer switch connector (it has continuity)
  • Red/yellow go to the headlight fuse
  • Blue/black reads 0V at the relay. I think if this was 12V the headlight would work
Questions for people:
  1. The headlight should come on without starting the engine right? Bike is disassembled so this would be a pain to test right now
  2. What is the purpose of this white relay? Is it some sort of headlight delay until the bike is started?
  3. What is this white wire going to the computer from the relay? I disconnected it and it has +12V on it at the relay
  4. Any suggestions on where to look next?
I’m out of ideas so my next step might just be to bypass this white relay and tie blue/black to red/yellow so the dimmer switch will be getting +12V.

computer behind battery looks like this one:
http://www.ebay.com/itm/07-Yamaha-V-Star-Custom-XVS-1100-ECU-CDI-ECM-Computer-Ignition-Module-SEE-VIDEO-/291265293515?pt=Motorcycles_Parts_Accessories&hash=item43d0c3accb&vxp=mtr
 

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Headlight on a 650 will not come on until the bike is started up. If you kill it out with the kill switch the headlight will stay on until you turn the key to off position. These are safety features to protect bike circuitry at start up and rider if bike is killed out.
 

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I agree with Rocketeer. On my '09 650 the headlight does not come on until the bike starts. I always assumed it was to make sure enough of the battery's power went to the starter. The spedo and the blinkers light up with the bike off but the key on, and they headlight is dark until it is running.
 

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Head light

Headlight on a 650 will not come on until the bike is started up. If you kill it out with the kill switch the headlight will stay on until you turn the key to off position. These are safety features to protect bike circuitry at start up and rider if bike is killed out.
I Have a 2005 vstar 650 , when I turn my key to the on position my headlight does come on with side lights etc.

conversely, is there supposed to be a light inside the speedo? I saw it mentioned in this thread.

Thanks and hope I shed some Light ...(bad joke)
 
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