TE610 electrical high beam issue

[kingsqueak]

So I'm installing a Lynx fairing on my 08 TE610.

I've got the harness all wired and patched in but.

I have low beam only.

No horn, no signals, no high beam.

I've checked all the Lynx harness, relays, fuses, it's not that. I flipped them all between the Low and High side of the harness all verified good.

The three Husky fuses are all fine, checked them too.

I traced back to the original bike side of the harness. I'm not getting power on the white wire that feeds the high beams. No power with/without the high beam switch on. No power with/without that switch on and hitting the passing beam switch.

I'm starting to wonder if the power on that wire comes through the instrument cluster. I'm horrible with reading schematics. The instrument cluster was unplugged and relocated to the new dashboard on the lynx so I have plugged and unplugged that connector a few times. I'm suspect that I'm losing it there somehow.

One other detail that I *hope* is not related. The fuel pump plug is pulled because I have the tank removed. That shouldn't have to be plugged in for this I hope.

Any suggestions appreciated.

A bit angry I did this to myself pulling apart a working bike heh...

 

[K7MDL]

The stock headlamp power comes from a main fuse to the ignition and handlebar switch. From there you get either high or low beam, not both. Exception to the both rule is the passing switch lights the high beam regardless of the hi/lo position. So in low beam the passing would have both on. In high beam it is redundant (no change), low beam is off. Speedo harness just monitors power is available to the headlight, no control, does not pass through.

For the Lynx the stock 5W city light (parking light) is used to power on the low beam Lynx relay powered from the battery via its own wire and fuse. The city light also feeds the tail light filament and as I recall has a separate 5amp fuse. I think the horn might be separate, not sure. When the key is on, or in park, the city light and tail light are also always on. That means the low beam in the Lynx is always on. When you swith to the Lynx high beam, that turn on the high beam relay and you now have both high and low beam. The original low beam headlamp wire is not used.

So with the rules above, you can trace power to the new relays, check the low beam lamp has power with key on, and high and low beam wires (at lamp) have power with switch in high position. You can check that power is getting through the switch to the control pins of the 2 relays. Check the Lynx and the parking light fuses.

Since you have the low beam working, that relay control comes off a separate fused parking lamp circuit, that proves the battery is working and the main power fuse for the Lynx is working (and available to the high beam relay) and most likely there is a stock fuse you missed for the main power since the horn is not working. I would also guess your fuel pump is not working and you cannot start the bike either. On the '08 I believe there are fuses located under the seat/side cover(s) as well as behind the headlight. Also there might be a blue ground wire on the '08 that you might have forgot to put back onto the battery terminal. I have a '07 carb model so going off recollection of others experiences here.

- Mike

 

[kingsqueak]

My fuel pump isn't working...because I have it unplugged as I removed the tank to do the work.

I'm getting this funny feeling that when I plug it back in tomorrow, my problems may go away. Could the fuel pump being out of line open the circuit I wonder....

We'll see tomorrow when I get back to it.

The only fuses aside from the ones in the Lynx harness that I'm aware of are three that are under the right rear side cover. Unless there are more that I haven't seen yet. I should look more closely for these I suppose.

I did manage to get all the cable routing issues from the previous owner alleviated. The clutch was routed up over top of the handlebar and was putting pressure on the housing against the bark busters...wore a spot through the vinyl.

Added my 2" Rox Risers and got all my cabling cleaned up today at least. Now I just have to get it running again. heh

Thanks for the reply.

 

[K7MDL]

The fuel pump is a load, not a conduit. It should have nothing to do with the rest of the system having no power.

Take another look at the ground wires on the negative battery post. Maybe you missed one when installing the Lynx cables? Use a volt meter and trace along a few points from battery outward to lights and see where is goes missing. Got to be something simple, likely something you touched (think what changed).

I have 2 fuses behind the headlight plus the Lynx fuses on my '07. The FI bikes changed this a bit, but with no power to the rest of the bike, it sounds like a cable connection to me assuming you found all the main fuses.

 

[Muddy Waters]

No horn, no signals, no high beam.

One other detail that I *hope* is not related. The fuel pump plug is pulled because I have the tank removed. That shouldn't have to be plugged in for this I hope.

Any suggestions appreciated.

A bit angry I did this to myself pulling apart a working bike heh...

I’m sure it’s not that simple but on my 08 610sm all those functions are not available if the motor is not running
And I guess it’ll be hard to do if the fuel pump plug is pulled ?

 

[kingsqueak]

Hahahah noooo waaaaaayyyy.

I *thought* that may have been the case, but I swear that someone told me that wasn't true.

O.k. I *have* to get this tank back on today. The bike has sat since July because I hit this 'problem' and hadn't had time to monkey with it.

I hope you are right.

 

[K7MDL]

RE: "Bike must be running" - That would be an odd design for a big bike. Definately not that way on the 06-07 (though key must be on). However pretty sure even on the '08 the city light/taillight is designed to be on when the engine is off (key in park), so that may explain why the low beam is working for you, since the low relay is off the city light wire, and power to the relay is from the battery direct.

If so must be saving power for the FI during startup? Good luck. I do not have '08 schematics handy here to look.

 

[Muddy Waters]

K7 you are right about the city light

My 08 have only two positions on the ignition switch; off and on, no park
Ones you move the key to on the city light do come on, along with the rear running light

(then if the dashboard display lightshow is not enough and you actually want to go for a ride you need to press the red “engine on” button and then the black “start” button )