Topic: Intermittent Headlight...electrical suicide watch!

[Chris Schneiter]

This thread was started way last summer, and only got worse...I was really active on this site, and when  things got really bad, I couldn't even think about my bike..so I guess I'm recovering because I'm writing..
Anyway...part of the reason I disappeared off the site is that my electrical problems got to the point where I couldn't even ride (It's killed me!).
   I had had an intermittent headlight, and finally tracked it down to the cut off in the starter switch. At the time, somebody said that probably the switch itself was deteriorating, and would eventually fall apart completely...well, it did..one day, the button went in and wouldn't come out.. When I tore it apart, a friend and I took out parts with tweezers (I think I'll post an email with a picture Monday).
   I found out that Honda still has the part (housing, starter switch, and kill switch) for about $100.00, and I found one used at Jeff's Cycle in Oregon. Don't EVER order from them! I ordered it the day after Hurricane Katrina...3 weeks, it didn't come..call Oregon.."OOPS! they didn't send it"..took my credit card number again...3 weeks..emailed them, to which they replied that they didn't have the part, but would refund my money...3 more weeks, they still have my money...then arrived the worst, peice of crap part you ever saw..much worse than what I'm taking off my bike! And the switch was broken! They still have my money...
At any rate, I seem to remember that the person who told me that the switch was deteriorating said that they just bypassed both the starter switch and the headlight switch (I can't imagine needing the kill switch). If I did that, how did you do it, and what amperage switches would i need for the starter and the headlight? I've found a bunch of switches that might work..or would it be better to go OEM?

[ProTeal55]

Sorry to hear about your bad luck....

I recenly removed all of the stock controls off my handlebars to clean things up a bit.
I moved the starter button to the left side cover, along with the key switch.
Went to the local Home Depot and got myself a 12 volt mommentary push-button switch.
Drilled a hole - and ran it thru the side cover, almost looks factory. 
Used some blue Loctite so the switch wouldn't move around.
See Pic below.............

[Dennis]

There are other options if you wish to maintain a stock appearance. ProTeals solution is certainly workable if your prefer that look. I noticed that he drilled an aftermarket cover. I would never alter my original F type covers.
I have a '75 CB750F with the starter button/headlight cutoff as you described on your bike even though you don't mention the specific model.
There are two options that I would consider.

Option 1
What I did with mine was to purchase an automotive general purpose SPDT (single pole - double throw) lighting relay (available at any auto stereo installer or alarm shop and maybe Radio Shack). The terminal configuration is the same as the original Honda switch. I disconnected the 3 wires to the headlight switch at the connectors before they entered the handlebars (there is an electrical box on the 750F) and made a little 3 wire harness to wire them to the relay without having to cut the OEM harness. I then took a small momentary push button switch and installed it in place of the starter button and ran the wires along the throttle cables to the relay. The headlight will draw about 4- 5.5 bepending on what beam or bulb you have installed. The relays are typically about 30 A, so that is no problem. Small push button switches are usually less than 1 amp, but that is fine to "pull" the relay. This does exactly the same function as the OEM switch with an almost original appearance and NO MODIFICATIONS to the harness if done correctly. The relay can be mounted in a convenient place preferrably shielded from roadspray if you have to ride in the rain. Mine is in the electrical box mentioned above. Another good location might be under the left side cover with the other electricals. The relay should cost about $3 - $6, but considering the way some suppliers set prices you may have to pay as much as $12. A small momentary push button switch should be no more than $1, maybe a little scrap wire, a few crimp on terminals to connect to the OEM harness and the relay a bit od electrical tape plus a few wire ties and you're done. I did mine for about $4.

Option 2:
Follow harness to connections prior to entering handle bars again. Find the 3 wires to the starter button. Connect power to headlight wire at this point(unplug headlight wire to starter button). Your headlight will be on whenever the key is switched on, including while operating the starter. Install a push button switch in place of the starter button. Connect power and starter wire to this switch.
Again an almost original appearance. Remember that the headlight DOES NOT shut off when operating the starter with this wiring.
If you wish to contact me directly for additional information feel free to PM.
This may sound difficult but it is really beginner level electrical, just hard to describe in words.

[mick750F]

   Yo Pro! I'm liking your starter button.

Mike

[ProTeal55]

Thanks Mick , It's the little things ..........

[Chris Schneiter]

Thanks...This is just common sense..I haven't decided if I want to go OEM or not..I just want it to get running again so I can do other things to it...once I started kick starting it, I realized just ho cold blooded it was..with the starter, it always started, but it just doesn't seem that I can get the kicker going fast enough...and I question just how strong the Kicker actually is..I'm wondering if they put those kickers on more for decoration!
Here's what was left of my starter switch when we too it out with tweezers! Oh! The Carnage! A viewer advisory to the un innitiated!

[Chris Schneiter]

And here's the crap part Jeffs cycle sent me! They seem to have a ton of parts, then they send you this! Note, the swtch, which is what I ordered it for, is broken!

[Chris Schneiter]

PS if you do want to check out Jeffs cycle, here's their URL..but be warned! http://www.JeffsCycles.com/