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ViragoTechForum.com Electronics No left flasher 1987 535 (SOLVED)
Poll :: Should I be doing this myself, or should I pay more $ than I earn for someone else to do it?

Stay at it
100%
 100%  [ 2 ]
Wait for advice
0%
 0%  [ 0 ]
Use hand signals
0%
 0%  [ 0 ]
Keep riding my Sportster
0%
 0%  [ 0 ]
Total Votes : 2



#1: Question No left flasher 1987 535 (SOLVED) Author: chasowen Post Posted: Mon Aug 23, 2010 10:24 pm

replaced stock flashers with Oberon bar end LEDs

Have steady power to right flasher unit (hear a crackling in flasher relay while it lights steady). Left side won't power at all (maybe a raw wire or short between switch and headlight bundle). Tried contact cleaning of switch . . . internal connections look okay, but ??? No power to left and no crackling in flasher like when I activate right flasher. I should note, left side flashers were inoperable when I got the ride. Tried attaching 4 amp load equalizer to the one right side flasher that works, but still steady light. I'm so confused

Any suggestions what to do next? I'd like to avoid re fishing all those wires and reconnecting the terminals for left handlebar switch, and I don't even know how to use the $20 multimeter I bought from radio shack doh



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turns on right flash, but not left?
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connections look clean after contact cleaner
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CIMG0006.jpg
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new ends and speedo on a drag bar
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Last edited by chasowen on Thu Aug 26, 2010 9:40 pm; edited 1 time in total

#2:  Re: No left flasher 1987 535 Author: chasowen Post Posted: Tue Aug 24, 2010 8:45 pm

UPDATE: In case anyone's interested. Learned a little about my new multimeter, and checked lot's of the wires in the flasher/switch system.

The dk green wire and black ground wire are currently powering the right flasher (which burns steady).

The chocolate brown wire from the flasher switch (handlebar) shows connection through to the flasher relay. The Chocolate brown wire from the left flasher unit shows connection all the way to the old, disconnected rear left flasher wire at the end of the harness. But when I seek connection from that left rear flasher wire to the flasher relay assembly . . . nothing.

I have two ideas, but no real understanding.

1) Maybe when I removed the indicator panel and taped the ends of those connections, I broke some necessary circuit between the left flasher wire (chocolate brown) and the right flasher wire (dk green). I mean, if there is some bulb that was between those two different wires, then maybe I should recreate that circuit somehow . . . like maybe the left side is pulling it's juice from that right side that's still working.

2) Maybe it's the flasher relay. Left side didn't work when I got it. The flasher relay assembly is imposing. It's electrical? Mechanical? I know it's expensive and I don't know if it's what I need. Most of the flashers out there appear a lot cheaper, but with 2-4 blade connectors and not 9 pins. Is there some way to test it? Fix it? Replace with aftermarket parts?
eek

#3:  Re: No left flasher 1987 535 Author: Baron Von Chaos Post Posted: Tue Aug 24, 2010 9:09 pm

So I have been thinking about this one for a while. I remember when I made my new wiring harness I had a similar issue with the flasher relay not working properly. I am not using LEDs but the whole thing is similar in nature. In the end, I managed to fry my relay and switch on my handlebar. I ended up getting a generic two prong vehicle flasher relay from the auto parts store and a different switch assembly from one of my other motorcycles and it worked properly.
I used this diagram to help with the process: http://viragotechforum.com/download.php?id=11241

#4:   Author: totallyredvirago Post Posted: Tue Aug 24, 2010 9:20 pm

as posted in your other thread..
your factory front signals also are marker lights (blue wire)
the left signal light will use the dark brown and black wires..
the right signal light will use the dark green and black wires...
leds need a resistor installed they do not pull enough current to work the flasher. now what i would do...
since you are cutting wires.. go back to the flasher (factory) unplug it. go to a auto store and get a 2 prong flasher and plug..
at the factory flasher plug cut the brown/white wire. splice this wire to one wire to your new flasher plug. go back to the factory plug and cut the brown wire (this is your feed wire) splice this wire to your new plug. put the flasher in you new plug turn the key on and watch your lights flash.....dan

#5:  Re: No left flasher 1987 535 Author: chasowen Post Posted: Tue Aug 24, 2010 11:02 pm

You guys are awesome for helping me. Maybe one day I will know enough to attempt a new harness like the Baron. Dan's idea sound's great for now . . . I wonder where there's an all night auto parts store?

But first, a few more questions:

What about the rest of the stock flasher unit and all the other wires in the connector? Does it go back on with just those two wires you mentioned removed and reconnected to the new 2 prong flasher?

Any particular type of 2 prong flasher since I'm using LEDs? And is the plug a part that comes with it? Anyone got a picture of one? Or a link to an add?

#6:   Author: 1986 XV700 Post Posted: Tue Aug 24, 2010 11:40 pm

You want a solid state (electronic) 2 pin flasher. They will operate without almost no lighting lighting load. When you buy the flasher tell them you need a plug (connector) to fit it. Splice the new flasher in as Dan said an plug the factory flasher back up and it should work. The factory flasher is your connection to your new LED's and the new flasher will provide the blink.

#7:   Author: chasowen Post Posted: Tue Aug 24, 2010 11:41 pm

Thanks guys . . . I'll be at the store bright and early

#8:  Re: No left flasher 1987 535 Author: chasowen Post Posted: Wed Aug 25, 2010 8:47 pm

Spent time soldering and tubing connections instead of the easy connectors; then experimenting with my multimeter to see why left side won't flash. Got the 2 prong flasher also, but waiting til I have power to left bar end light before I add the prongs. This is what I found:

1. There are two dk brown wires (left flasher) from handlebar now . . . one comes from handlebar switch, other attached to left side LED lights. They both have connectors inside the headlight (9 pin for switch, bullet for left LED light) that both lead back into the main harness under the top frame.

2. There are two other dk brown wire ends on the bike: one is for the rear left light, another exits the main harness in front of the top frame and behind the steering column (this used to go to the indicator light panel).

3. Continuity - there is continuity from the left rear wire end to the old indicator wire and all the way to the new left bar end light. There is no continuity between any of these points and the wire running from the switch back toward the harness.

So...

4. Current - when the switch is pushed right, all is well, but when the switch is pushed left, no nothing. However . . . there IS CURRENT being delivered from the switch along the wire going back into the harness! I't just not getting to the rest of the dk brown circuit that goes to the lights. In fact, when I reversed the hookup of right light to left switch, the left side actually lit up, but the right side would not. And when I jury rigged the dk green and dk brown together (as though there were an indicator light in between), a push to the right lit both bar ends, and a push to the left resulted in . . . you guessed it . . . nothing.

hairpuller

I am guessing that there is a broken splice between the two lines of dk brown wire somewhere in that nasty, sticky wiring harness. I don't see any other connectors in the diagram that might be fowling up the left side circuit.

QUESTION: sound like I'm on the right track? What's the best way to find it? If I have to cut through that sticky mess, how do I get it out from that frame tunnel without having to take off all of the connectors, and how do I re Wrap it nice and clean? I feel like I've bitten aff a lot, but I am really having too much fun. Also wondering if you guys have any good sources or recomendations for types and sizes of shrink tube.

#9:   Author: totallyredvirago Post Posted: Wed Aug 25, 2010 9:09 pm

is the rear left light flashing??
there is a factory splice before the 9 pin connector.. what you need to do is. right below the handle bar find the one and only dark brown wire coming out of the switch.. prob this wire with a test light. turn your key on. (flasher plugged in) switch to the left. test light will flash.. if it dont then you have a bad switch....dan


Last edited by totallyredvirago on Wed Aug 25, 2010 9:35 pm; edited 2 times in total

#10:  Re: No left flasher 1987 535 Author: Baron Von Chaos Post Posted: Wed Aug 25, 2010 9:21 pm

Beat me to it! Now as for heat shrink, I get mine at home depot. It's $1.99 for an 8 pack of 3/8 inch. Radio shack has it for $6 for a 12 pack of assorted colors and sizes. All are about 3 inches long, I just cut them in thirds.

#11:  Re: No left flasher 1987 535 Author: chasowen Post Posted: Wed Aug 25, 2010 10:26 pm

Well . . . I didn't use a test light, just my nifty new multimeter:

When I turn the switch left, I get voltage from the switch through the 9 pin connector in the headlight . . . switch off and no voltage . . . so it shouldn't be the switch, right? And when I reverse the two flasher circuits (attach the starboard dk green circuit to the chocolate brown switch wire), I get power through switching left to the right side lights. I don't see how it could be the switch . . . the problem is getting the juice from the switch through to the line with the lights on it. I'm still thinking a bad splice up in the harness.

PS I'm having so much fun I just bought a mess of heat shrink stuff online. I'm sure it'll come in handy when we start to tear apart my daily ride.

#12:   Author: totallyredvirago Post Posted: Wed Aug 25, 2010 11:00 pm

ok the right side works normal (front and rear flash)??
if so..
take the green wire and hook it up to the left side.. select right turn on the switch and see if the left side flashes (front and rear). if the left side does flash with the green wire then the signal lights are ok..
the problem is in the dark brown wire..
now i recommend for you to get a test light. hook the clip to a good ground.. turn the key on select left turn probe the dark brown wire close to the switch.. if the test light does not flash.. you have a bad switch.. if the wire flashes then take you test light down the harness probing the wire until you dont have the flash any more... you just found your break....dan

#13:  Re: No left flasher 1987 535 Author: chasowen Post Posted: Wed Aug 25, 2010 11:13 pm

Thanks man . . . don't have a test light, but the multimeter reads 9-12V on that line when I switch left (same as on the right). I'm gonna try to probe the wire back into the harness to find a break tomorrow . . . . any recommendations about working through that area that goes through the upper frame?

#14:  Re: No left flasher 1987 535 Author: Baron Von Chaos Post Posted: Thu Aug 26, 2010 3:08 am

Just a thought, but couldn't you make like wiring harness specifically for theturn signals at least for testing purposes?

Now as for your poll... you know my vote.

#15:   Author: totallyredvirago Post Posted: Thu Aug 26, 2010 6:10 am

if you use the green wire like i said and the lights work.
you can cut the dark brown wire close to the switch and splice in a new wire.. but i what you to be sure that it is a wire problem and not the switch.....dan

#16:  Re: No left flasher 1987 535 (SOLVED) Author: chasowen Post Posted: Thu Aug 26, 2010 9:53 pm

rock on Thanks very much fellas . . . your advice has been invaluable. I ended up splicing the left flasher switch line (chocolate) to the continuous left flasher line (chocolate) back behind the connectors in the headlight and old indicator connector. I can only imagine that there is a break in whatever factory splice lies deep in the harness. splicing the two ends of the two lines seems to have recreated the circuit. Left switch gives left light, right switch gives right light.

Tomorrow I will make them flash as per Dan's easy peasy instructions.


In the meantime, thanks again . . . pictures of wiring are kind of boring . . . but I will put something up soon. Peace
ViragoTechForum.com Electronics No left flasher 1987 535 (SOLVED)


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