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Discussion Starter #1
Hey Strommers

I'm currently touring Croatia and today my DL650A wouldn't start.
I got on the road again by shorting the starter motor.

A lokal mechanic mad a temporary solution by hooking the O/W and Y/G wires up to an external starter button.
So far so good, now she starts.
But I have no headlights?

As I understand it the headlights are hooked up to the start button to dim them when you crank it. But I can't claim to understand how it works.

How do I get them working again? Would prefer not to ride across most of Europe without headlights. ?

Hope someone can help.

Regards and good riding.
 

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Hi

What year is your bike? There is some variation on the design, but the start button has some spring-loaded contacts that get dirty and bind up. Some people say you need to install aftermarket wiring to fix the issue. This isn't necessary. The best way to proceed is to very carefully disassemble that switch, clean it with a rag and some electrical contact cleaner, and reassemble it. Take pictures and notes step-by-step to be certain everything is in the right place, and drape a towel underneath the area to catch any falling parts.
 

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Discussion Starter #3
It's an 08.
The mechanic cleaned the switch thoroughly and tried to get it to make contact but with no luck.
I'm guessing it has something to do with the other 2 wires to the switch that are now connected to a non-functioning switch?
But I'm at a loss of what to do with them. ?
 

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The starter button has 4 cables, two connected to a normally open circuit and operates the starter. The other two are connected to a normally closed circuit. This circuit operates the lights. The idea is when you hit the starter button the lights turn off.
To fix the lights the only thing is to connect the cables together or to install a switch to close the circuit.
My bike burned out the contacts on the starter switch so I just soldered the cable together.
Hope this helps
 

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Check the big plug on the left side above the radiator you could have a burnt connection on a wire or two.
 
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Discussion Starter #6
Yeah, pondered it last night and i will probably need a switch more.
Will try to disassemble the switch and short the other 2 wires. If that gives me light I will try to find a switch somewhere.
 

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Hi Chaneera, have you taken a peek in your fuse box lately to confirm the problem isn't a fried headlight fuse? If all good there I would recommend you follow Rolex's advise and check the "big plug".

You should always have some dielectric grease and contact cleaner handy when working on electrical components and apply it prior to putting things back together to help prevent future problems.

Good luck!
 

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Discussion Starter #9
Quick follow-up.

Bought a cheap switch from a hardware store and mounted it so I could do the sequence manually (turn off lights -> hit the starter -> turn on lights). It will do untill I get a replacement.
Not pretty but it works.

Will most likely also need a new switch for the clutch.
 

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For others there is another way to keep your headlights off when staring your bike.

With your right hand push and hold the start button.

With your left hand turn on the ignition.

(This will bring on your dash but not your headlight)

With your left hand pull in the clutch, this will start the bike.


The headlights will stay off until you release the start button.
 
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Um, why would you want to do that?


For others there is another way to keep your headlights off when staring your bike.

With your right hand push and hold the start button.

With your left hand turn on the ignition.

(This will bring on your dash but not your headlight)

With your left hand pull in the clutch, this will start the bike.


The headlights will stay off until you release the start button.
 

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In theory, there is less arching to take place on the starter button contacts. Under normal conditions, when the starter button is depressed, a set of contacts (on the button), disconnect the lighting circuit and move over to complete the starter circuit. Arching takes place each time the starter button is depressed.
 

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Yup, easier on the starter button contacts and less load on the battery during start ups. That's a very smart technique.

Sent from my SM-G930V using Tapatalk
 

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As they have said if you think your battery could be low on voltage for "any reason" or your start button is giving trouble you can use that method till you get things fixed up.
 

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if I recall some have reported burned/fried connectors in the circuit besides the starter switch so a headlight relay to take the load off the whole circuit would be the best way to prevent future problems (once present problems are corrected) the thought of losing headlights at night was enough to motivate me.
 
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