Headlight GL1500

1328 Views 14 Replies 6 Participants Last post by satan, Sep 28, 2009

awall4400

Discussion Starter · Sep 25, 2009

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I have a 97 Aspencade went on a ride Sat. cruise come on but would not set Checked fuses and relays all seemed good. Went to check and now headlight does not work,bulbs work with battery charger. All other lights work except headlight and cruise still does not work. Anyone have any ideas?

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DBohrer

· #2 · Sep 25, 2009

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Need more information.......

Does the low or high beams work? Or are they both out?

The two problems are probably independent of each other.

If your "cruise on" indicator light on the dash comes on, then it is a cruise set problem.

There are micro switches (one each) at the clutch and brake levers. Sometimes those switches do not complete the circuit and allow the cruise control to be set.

While trying to set the cruise control, push out on the clutch lever. If it sets, the clutch lever is not pushing the pin in far enough to activate the micro switch.

If that does not work, try the same thing with the brake lever.

There are brass bushings on the clutch and brake levers, sometimes they become worn and prevent the levers from activating the micro switches.

If that does not work, pull up on the rear brake pedal while trying to set the cruise control. There is also a switch (not micro) at the rear brake pedal. This is an adjustable switch.

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exavid

· #3 · Sep 25, 2009

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If the fuses are good and the headlight is the only thing not working it would be worth checking the starter switch.

GL1500 Starter/Reverse Button Fix

It has contacts that open up when you hit the starter to reduce the starting load on the battery. If those contacts are burned or dirty or the connections to the switch are in bad shape the headlight won't come on. If you don't have an ohm meter you can check the switch by shorting the two terminals. If the headlight lights up the switch is bad.

DBohrer

· #4 · Sep 25, 2009

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There is only "one" headlight fuse, it is a 15-amp fuse in the # 5 position.

The starter/reverse switch can be bypassed by jumping across the brown/white and the blue/white wires.

awall4400

Discussion Starter · #5 · Sep 26, 2009

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Thanks for the help, I got the headlight working by spraying brake cleaner in the starter switch. Haven't got a chance to mess with the cruise yet. Thanks again

Bike...and Dennis

· #6 · Sep 26, 2009

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I'm betting the cruise problem is the rear brake light switch. Follow the spring from the pedal and work the switch a few times. 15 second fix for the same problem as the headlight...dirt.

awall4400

Discussion Starter · #7 · Sep 26, 2009

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The cruise was the clutch handle switch, when you pull the handle there should be two clicks I had only one. The switch was good I had to move it a little closer to the handle now it works fine. The brake handle works the same way there should be two clicks. Thanks for the advice.

Bike...and Dennis

· #8 · Sep 26, 2009

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Got it working, huh? Good deal.

All those switches and buttons seem to be weak points so you'll know where to look first the next time there's an issue.

Now get out there and put 50k on the bike before the snow flies. :action:...oops, North Carolina...before the sand flies? Before the Wright brothers fly? Before the sand flies fly?

DBohrer

· #9 · Sep 27, 2009

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awall4400 wrote:

Wing-Rider

· #10 · Sep 27, 2009

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DBohrer wrote:

Need more information.......

Does the low or high beams work? Or are they both out?

The two problems are probably independent of each other.

If your "cruise on" indicator light on the dash comes on, then it is a cruise set problem.

There are micro switches (one each) at the clutch and brake levers. Sometimes those switches do not complete the circuit and allow the cruise control to be set.

While trying to set the cruise control, push out on the clutch lever. If it sets, the clutch lever is not pushing the pin in far enough to activate the micro switch.

If that does not work, try the same thing with the brake lever.

There are brass bushings on the clutch and brake levers, sometimes they become worn and prevent the levers from activating the micro switches.

If that does not work, pull up on the rear brake pedal while trying to set the cruise control. There is also a switch (not micro) at the rear brake pedal. This is an adjustable switch.

I know it's fixed now but we seem to forget about one cruise cancel switch. The throttle. If that one is activated or stuck in the canceled position, no cruise set either.

DBohrer

· #11 · Sep 27, 2009

imported post

Wing-Rider wrote:

DBohrer wrote:

Need more information.......

Does the low or high beams work? Or are they both out?

The two problems are probably independent of each other.

If your "cruise on" indicator light on the dash comes on, then it is a cruise set problem.

There are micro switches (one each) at the clutch and brake levers. Sometimes those switches do not complete the circuit and allow the cruise control to be set.

While trying to set the cruise control, push out on the clutch lever. If it sets, the clutch lever is not pushing the pin in far enough to activate the micro switch.

If that does not work, try the same thing with the brake lever.

There are brass bushings on the clutch and brake levers, sometimes they become worn and prevent the levers from activating the micro switches.

If that does not work, pull up on the rear brake pedal while trying to set the cruise control. There is also a switch (not micro) at the rear brake pedal. This is an adjustable switch.

Click to expand...

I know it's fixed now but we seem to forget about one cruise cancel switch. The throttle. If that one is activated or stuck in the canceled position, no cruise set either.

I did not forget about the throttle cancel switch. It is in sequence between the cruise cancel switch (at the front brake lever) and the cruise cancel switch (at the rear brake pedal). It does not get used as frequently as the micro switches at the clutch and brake levers, nor as frequent as the cruise cancel switch at the rear brake pedal.

I have been riding and wrenching on GL1500's for about 20 years and have never know of a throttle cancel switch failure. Of course it is always possible, just about anything is....!

But I have known of many many problems with the micro switches.

Therefor, not a lot of reason to mention the throttle cancel switch when advising folks about troubleshooting cruise control set issues.

Plus the fact that it is considerably more difficult to access than the other cruise cancel switches.

The above reasons are why I don't usually mention it when making suggestions for troubleshooting cruise control set issues.

It is always best to "first check" the items "that fail most frequently" before moving on to other things.

However, it can be easily tested if one knows where to connect the ohm meter.

PS: I like you comment: If that one is ("activated" or stuck in the canceled position), no cruise set either.

Are you aware the switch "has to be activated" which completes the circuit and allows the cruise control to set??

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awall4400

Discussion Starter · #12 · Sep 27, 2009

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Yes I found that out when I checked it with the OHM meter. I think maybe I need to replace the starter switch it is still sticking. I can spray contact cleanerin it and it will work several times then quit working. Is there anything I can do short of replacing it.

Bike...and Dennis

· #13 · Sep 28, 2009

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awall4400 wrote:

Yes I found that out when I checked it with the OHM meter. I think maybe I need to replace the starter switch it is still sticking. I can spray contact cleanerin it and it will work several times then quit working. Is there anything I can do short of replacing it.

It's best to remove and dismantle the switch to clean it. Be careful, there are some small pieces and springs in there.

If I remember right, I had to bend something to allow for the 20 years of wear. It can be fixed though.

awall4400

Discussion Starter · #14 · Sep 28, 2009

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Thanks i'll give it a try when I get a chance. Let you know how it turns out

satan

· #15 · Sep 28, 2009

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awall4400 wrote:

The cruise was the clutch handle switch, when you pull the handle there should be two clicks I had only one. The switch was good I had to move it a little closer to the handle now it works fine. The brake handle works the same way there should be two clicks. Thanks for the advice.

I'm sure you've all had a look -- but...

... In my few exposures to the clutch swithc cruise failure I've found that looking at the bushing there that presses in the Clutch Master Cylinder pin is warranted. I've found most of these VERY worn (one was even worn through with the clutch master cylinder pin rubbing into the bushing's bore in the clutch lever. (eek!!)

At the very least, it's worth a good lube and inspection. Glad you got the Cruise going again!

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