With all the reports of headlight problems, I thought it would be a good idea to gather some information on how big the problem is.
greywolf
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I have a 2012 DL650. I have tried all of the repair hints with no success. What is the relay fix you mention? I cannot find the the connector on the right side of the fairing. I have cleaned the switches on both the handlebars. I pulled the gas tank and checked and cleaned the connectors there. Fuses are good. Bulbs are good. I can put 12 volts at the fuse holder and get lights. What am I doing wrong?
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The connector is on the left side.
Inside a big rubber boot.
Easternbever do a plug and play relay kit, it takes the load off that plug and the starter button.
You can build your own cheap with parts from online stores if you have the skills, if not just buy the EB kit to stop any future problems.
Inside a big rubber boot.
Easternbever do a plug and play relay kit, it takes the load off that plug and the starter button.
You can build your own cheap with parts from online stores if you have the skills, if not just buy the EB kit to stop any future problems.
I unpluged that plug and it looked good. I sprayed the plug with contact cleaner and applied dielectric grease. No change. Is there a schematic to build the relay? Thanks for your help.
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You need a test light to check for power and ground on both sides of the plug.
A meter is not good enough as it puts no load on the system, I use an old headlight globe for testing as it's a good size load.
You can buy H4 headlight relay kits online, they are made for cars so you will need to shorten the wires, get 2 one for low beam & one for high.
Ground and power wires go directly to the battery the trigger wires will go the Suzuki headlight plugs, one in the low beam socket the other in the high.
A meter is not good enough as it puts no load on the system, I use an old headlight globe for testing as it's a good size load.
You can buy H4 headlight relay kits online, they are made for cars so you will need to shorten the wires, get 2 one for low beam & one for high.
Ground and power wires go directly to the battery the trigger wires will go the Suzuki headlight plugs, one in the low beam socket the other in the high.
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6,273 Posts
Please don't think that by adding headlight relays, that this fault will be solved. The purpose of the headlight relays is to help take the load off the starter button and to a degree to protect the wiring harness of the headlight circuitry.
However, you still need to sort out whatever is currently the cause of the headlight failure on your L2 Glee. Reply #15 in https://www.stromtrooper.com/thread.../threads/electrical-ghosts-need-help-with-my-commuter-bike.432172/#post-5511683 has a wiring diagram attached, that can aid you to determine the wire colors involved as well as the electrical path of the headlights circuit.
For the record, remote diagnostic is difficult for me without being able to see exactly what is taking place during the testing process. If you don't mind, please provide indepth feedback on what you are looking at and where you are testing, etc, so that I (we the members) can see through your eyes on what is is being done in the diagnosing process.
However, you still need to sort out whatever is currently the cause of the headlight failure on your L2 Glee. Reply #15 in https://www.stromtrooper.com/thread.../threads/electrical-ghosts-need-help-with-my-commuter-bike.432172/#post-5511683 has a wiring diagram attached, that can aid you to determine the wire colors involved as well as the electrical path of the headlights circuit.
For the record, remote diagnostic is difficult for me without being able to see exactly what is taking place during the testing process. If you don't mind, please provide indepth feedback on what you are looking at and where you are testing, etc, so that I (we the members) can see through your eyes on what is is being done in the diagnosing process.
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7 Posts
Use baking soda and super glue and simply polish do not buy the whole unit this will work for many plastic to Plastics for lots of things it's like concrete and can be buffed grinded or polished good luck if you haven't done it yet
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Just joined - Thanks for the valuable resources I found here.
Found no headlights on my 2012 DL650 last month. Checked likely spots in order of disassembly required. The black 8-pin plug on the radiator shroud had a pin get so hot that it plastic welded the plug shut. Had to partially destroy the plug just to find out what was going on inside. I was able to relocate the pins to the open position, since only 7 out of 8 pins are used in this plug.
Edit Found out more about the coupler option here after a quick search. https://www.stromtrooper.com/posts/5769805/
Thanks, again!
Found no headlights on my 2012 DL650 last month. Checked likely spots in order of disassembly required. The black 8-pin plug on the radiator shroud had a pin get so hot that it plastic welded the plug shut. Had to partially destroy the plug just to find out what was going on inside. I was able to relocate the pins to the open position, since only 7 out of 8 pins are used in this plug.
Edit Found out more about the coupler option here after a quick search. https://www.stromtrooper.com/posts/5769805/
Thanks, again!
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