1982 xj1100 headlight problem

[bbbiscuit]

1982 xj1100 10k miles. the headlight works and sometimes it doesn't. the problem seems to be getting worse. removed the lamp and tested the plug with no apparent power during one of its episodes. i have also had an intermittent problem with the bike quitting when pulling in the clutch and putting into first gear. maybe a safety switch ? are these two problems related?

[Axel]

No headlight

I had an intermittent headlight thing going a while back . A friendly fellow went straight to the fuse block and the fuse was faulty . It looked good at a glance but something was actually melted inside . We also used a dremel tool with wire brushes to clean the fuse holders . They are open to the air and get less conductive over the years . Better than new fuse blocks are available . I read about them here somewhere. Oh , and The PO had used a longer fuse than OEM - maybe that started the problem . Good luck . Axel

[Axel]

similiar thread

Use the search to find similiar threads or just info about xj11's.
Lots of people have them . This is a little different problem but has links and lots of info .

my xj1100.....still having problems!

Hope that works . Axel

[Axel]

http://www.xs11.com/forum/showthread.php?threadid=14152&highlight=clutch+safety+switch

[Axel]

safety switches

Some of my safety switches work and some are disabled . I was surprised at the extent of the wiring and diagnostics . I'm sure the clutch lever switch is disconnected or shorted to cause an "ok" condition . So there was a problem there for the PO . Many electrical problems can be righted by cleaning connections.

Axel

p.s. where you from bbbiscuit ?

[frogdink]

i had the exact same deal and it was the fuse that was all but blown, changed it now its always fine

[DELL82]

Had the same problem, but I have already changed the fuse block to the mini spade type, so that was not the problem. The XJ has a large lighting module under the seat that has a plug connected to it with eight connections. Cleaned that up and problem went away. PO had removed and wired around two of the contacts because of excess corrosion.
Good luck
Dell82

[Rubin]

Found this on a search for ways to upgraded the headlight and wiring:

http://www.eautoworks.com/html/ORD-1-1-1-Psub171170.cfm

Looks interesting, though discontinued. They might have stock available still, will email them to find out.

[Rubin]

No luck, discontinued and no leftover stock. Too bad.

[scott0757]

Seacrh for a Forum thread named fuse block and you can get a spade type replacement from TCat.

[Fuse Block Thread

I just installed one on my 1980XS1100SG this past weekend and it went easy. The two extra slots in this 6-fuse holder hold the spare fuses.