• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Headlight not working low voltage at plug.

Hondarider21

Hondarider21

Husqvarna
B Class
Hello everyone, my first tech post. Lil catch up. I was . Full time powersports tech up until 5 years ago, been around this stuff fmost of my life. Just recently acquired a 08 husqvarna 610 sm to commute and play around on the weekends. Bike is in good shape, but horribly maintained. First and foremost do we have a current link to a service manual I could download. Second is my current situation. I've got a headlight not working, bulb is good as I tested it. Running light works but that's it, no hi or low beam. After doing very testing so far I've only got 8-9 volts at the headlight plug. Battery voltage is great, voltage in and out of the fuses is good, and that's as far as I've gotten. Did find 1 corroded relay which I cleaned up. Lil side note, for some odd reason they've removed all the turn signals, horn, and possibly the horn relay. And replaced the taillight with a eBay led light Why I'll never know. So I've got a lil work ahead of me. I've got it tore down, to do a timing chain and tensioner replacement, and install a pcV, slip on, and power up kit. And fix a few things. Ie. Missing bolts, fluids, etc. What lil I have road it out seems it'll be a great bike after I get it sorted. Sorry for the book. So any pointers for a ol KY guy?
 
Go to husqvarnaoutlet.com, and you'll find links to parts fiche and repair manuals for most Husky models. The repair manuals have wiring diagrams, this should help. but other than that, I'm dealing with wiring issues of my own. I hate electrical gremlins.
 
I had a similar issue and it was voltage drop in the wire from the VR to the Battery. I had 3V at the healight, 9V drop in the wire. Problem turned out to be the main fuse. Replaced it and all was fine.
 
Thanks, I'll order a service manual. And check the fuse also. So far I've found the relay wire yellow with green stripe isn't grounding. Ran a jumper ground wire and nothing. But if I run that pole hot I get voltage at the headlight. Wtf! I need a service Manual.
 
There's also so. SomE type of resistor at the main fuse, starter relay.
 

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Ok lil recap of this evenings work. This isn't going to make any sense, and I'm hoping someone on here with more husky knowledge will come in and tell me why. The supposed ground for the headlight, turn signal, horn relay has very minor voltage through it. Like. 09 volts. It also won't act as a ground. So I made a jumper ground. Thought that would solve the issue. Nope! The relay is now working as intended, but still no voltage at the headlight, horn, or signals. Now here's where it gets weird. I can hook the yellow and green wire that is unhooked from the relay, and a supposed ground to the positive side of the battery, and everything works as intended. So to recap, I pulled just the supposed ground from the relay, ran a jumper ground, then hooked the factory yellow and green ground to a hot, and all works. I called it a night, as the beer started taking over, and none of this makes sense.
 
So any husky guru's for any idea why this is the way it is, in bit to just wire it up the way it works, and let it ride.
 
Lil bump for ideas, I'll be working on her again tonight. At this point, I'm thinking I'm gonna wire it up the way that will make everything work, and let it ride. Right, wrong, or indifferent, it works. Lol
 
Not following everything 100%... have you verified that the ground terminal at the bulb is grounded?

If you've got a way that works I'd run with it. Our wiring harnesses are known to be a little fragile, my guess is you've got a broken or chaffed wire somewhere.

.
 
I have verified a good ground. But regardless of that, I shouldn't be able to feed a factory ground wire 12v, and not have a fireworks show or fire. Lol . But yeah, like I said, just gonna write it up the way it works and ride.
 
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