ZL600 Headlight dead

[Steve C]

Hey folks,

So I am really hoping you guys can help me out. The other day I was adjusting the valves on my 86 ZL600 (which 15 of 16 were significantly out of spec btw) and to rotate the engine into position I was bleeping the start button. My problem likely arose from the fact that I forgot to disconnect my trickle charger before bleeping away, and after a few bleeps my headlight quit. Not thinking much of it, I assumed I had either blown the bulb or fuse. However, after checking with the multimeter I found that the headlight plug and even the headlight circuit in the fuse box had no juice at all. I did check to see that at least the tail light circuit still had juice but since the bike will turn over and all lights work, I figured it was only that headlight circuit. t

I have looked at the wiring diagram but I can't seem to make out where else in line I am losing power between the battery and fuse box for only that headlight circuit. If anyone can help me out I would REALLY appreciate it!!!

 

[Blue-Grass-Tornado]

I know on the ZL900's, the headlight circuit is dead, even with the key ON, until you actually hit the start button one time. Then it comes to life. How are you testing it?

 

[Steve C]

I am testing with the multimeter in terminals in the plug for the bulb with the key on. The light should be coming on when the key is on :/, not only when started...or at least mine had been before.

 

[furchin]

" The light should be coming on when the key is on :/, not only when started...or at least mine had been before."

The head light should NOT come on with the key in the start or run position until the start button has been pushed. I would simply replace the fuse along with a new head light bulb or at least meter these two items to double check their status.

 

[Reptar]

^^^^ The Headlight should not have any power going to it at all untill the motor starts, key or no key.
if you have the stock H4 plug I would suggest ppicking up a replacement to swap out, or hold on to in case it decides to do what mine did in the florida heat, and melt into a lump.

 

[Steve C]

" The light should be coming on when the key is on :/, not only when started...or at least mine had been before."

The head light should NOT come on with the key in the start or run position until the start button has been pushed. I would simply replace the fuse along with a new head light bulb or at least meter these two items to double check their status.

Well I can tell you unequivocally that when I turned the key before the valve job that the light was on and shinning bright against my garage wall, and after a few blips of the starter to rotate the engine she stopped. I did check the headlight plug and circuit in the fuse box with a multimeter and with the key on they are both dead. Have not been able to see what happens when running as I am waiting for new carb boots and things are apart. :/

 

[Steve C]

^^^^ The Headlight should not have any power going to it at all untill the motor starts, key or no key.
if you have the stock H4 plug I would suggest ppicking up a replacement to swap out, or hold on to in case it decides to do what mine did in the florida heat, and melt into a lump.
View attachment 21010

Wow, sorry about that plug! My plug also seems to be original and in good shape...no melting or burning yet. I just don't understand why my bike WAS absolutely shinning the headlight with just the key on and bike not running prior to my work and mid way it decided to start doing what it was supposed to? All that is fine by me if it works when running like you guys say.

 

[Steve C]

Well not that I doubted you guys about the light coming on only when starting but it was cool to find this video of my year and model doing as you say, https://www.youtube.com/watch?v=NXWCzgygZdc

So I am a little puzzled by why the light was going on before the bike started before...but I can't say I care if all is well when I ride