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Message started by kylejang on 05/01/18 at 19:09:00

Title: Horn and Headlight is not working Help
Post by kylejang on 05/01/18 at 19:09:00

Hi Today found more problems. Headlight and horn is not working.
Is there any fuse for headlight and horn?
Last Saturday I replaced OEM horn to Fiamm's 12V 130 dB "FreeWay Blaster" Low Tone Horn and that day worked fine.
Today I found out horn is not working so I started to check more and also headlight is not working too. Is it coincident?
Yesterday I sprayed WD40 to clutch lever and it was dripping.
Now I know there is electrical connector under the clutch lever.
What could possibly went wrong? Please give me advise. Thank you :'(

Title: Re: Horn and Headlight is not working Help
Post by batman on 05/01/18 at 20:05:48

The switch on the clutch lever is a safety in the starting circuit ,and has nothing to do with your lights. The turn signals ,headlight and horn all share a common ground(black -white stripe) , that leads back into the harness .It maybe helpful to get a volt/ohm meter and look in the Tech Section at a wiring diagram before you change things from stock.did you hook the wires to the new horn backward? The black& brown wire is the pos. the green wire is the neg.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/01/18 at 20:17:32

Turn signals work good. So if I want check for wiring harness where I should start look for?

Title: Re: Horn and Headlight is not working Help
Post by batman on 05/01/18 at 20:54:10

I've added t my above post -reread. If you've blown a fuse you may have hooked the horn wires up backward.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/02/18 at 08:14:08

How many fuses Savage or 07 S40 in total?
I only know 2 fuses(main) under the seat.
I thought horn is not sensitive to polarity.
Please let me know more I am learning so much from you guys.
Have a good day everyone.

Title: Re: Horn and Headlight is not working Help
Post by Dave on 05/02/18 at 08:22:12

The original horn is not grounded....if the new horn has a connection to ground and you have the wires reversed - there is a possibility it will create a short that will blow fuses.

Your new horn may draw more amps than the existing fuse or horn button can tolerate - you may blow fuses and could burn up the horn switch (or the relatively small wiring that supplies power to the horn). It may be necessary for you to install a relay - the horn button will be used to energize the relay.....the relay will provide power from the battery to the new horn.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/02/18 at 09:16:23

Thank you Mr. Dave and Mr. Batman .
If new horn toast fuse and then why head light is not working?
Is there any seperated fuse or relay box for horn or head light?

Title: Re: Horn and Headlight is not working Help
Post by kojones on 05/02/18 at 10:31:26

063D3027363A21273C343926550 wrote:

The original horn is not grounded....if the new horn has a connection to ground and you have the wires reversed - there is a possibility it will create a short that will blow fuses.

Title: Re: Horn and Headlight is not working Help
Post by kojones on 05/02/18 at 10:44:16

I would check the connector under the tank, the one that connects the left side handlebar controls to the wiring harness.

Title: Re: Horn and Headlight is not working Help
Post by batman on 05/02/18 at 14:24:56

Of course the horn is grounded! or it wouldn't work! everything electrical on the bike is grounded, or there's no complete circuit. disconnect the horn and see if your headlight works again, you may have to try both the high and low beams (don't be surprised if one doesn't work) ,then hook the horn up swapping the wires from before. The only reason your turn signals work is you didn't have them on when you first tried your horn.,but your headlight was on ,even if you didn't blow a fuse (And there are only the two you mentioned ) you may have toasted the headlight filament .

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/02/18 at 17:45:49

So far I checked
Both fuses look good - tested with spare fuse/

Headlight
1. headlight bulb - filament not burn , I check with extra bulb same result - no light.
2. headlight without connecting OEM horn - no light.
3. headlight with connecting OEM horn - no light.
4. wiring and connectors - no pinched area looks ok
5. under gas tank( I disconnect tank today make sure I can see wiring and connectors) - no pinched area looks ok.
6. testing low and high beam without horn - both no light
7. testing low and high beam with OEM horn - both no light
8. also passing buttom is not working too

Horn
1. OEM horn without headlight bulb - no horn
2. OEM horn with headlight bulb - no horn
3. switching wiring connector - no horn

I think horn and headlight are not getting power at all.
Is there any relay that sending power to horn and headlight when key is on position?
Should I test horn button, passing button, high and low beam button with voltmeter check to see if they are getting power?

Title: Re: Horn and Headlight is not working Help
Post by batman on 05/02/18 at 18:38:45

YES you should test everything with a volt/ohmmeter including the fuses, and you can remove the headlight bulb and test it for resistance(ohms) and the headlight socket to ground for voltage ,and the horn wires also . I would not expect the horn ,headlight ,and passing switches to all go bad at once , but the power for these all run through the large connector that sits just above the spark coil.

Title: Re: Horn and Headlight is not working Help
Post by Dave on 05/03/18 at 04:10:14

7D797C79787365160 wrote:

[quote author=063D3027363A21273C343926550 link=1525226941/0#5 date=1525274532]The original horn is not grounded....if the new horn has a connection to ground and you have the wires reversed - there is a possibility it will create a short that will blow fuses.

The horn is grounded or the horn switch grounds it, it has to be as it is a 12V horn and the bike has 12V electrical system. And I don’t think there’s any harm to have the wires reversed, the horn is so simple device (unless it has an amplifier and a speaker) that it can only be less loud when the wiring is reversed.[/quote]

Sorry....I seemed to have typed something that was misleading.

The original horn is not grounded through the mount. There are two wires that lead to the horn.....one is hot all the time, the other wire leads to the horn button - when you push the horn button it provides the ground and completes the circuit.

If the new horn provides a ground through the mounting arm - you need to be sure you don't connect the power wire for the horn to a connector that is also connected to the grounded mount for the horn. (If your new horn has two connectors or wires....I suspect the mount is not grounded).

There is a larger orange wire that takes all the power up to the left electrical control on the handlebars. That is where all the power is supplied for the headlight, and horn. The turn signals are provided power through a separate wire that passes through the flasher unit before the power is delivered to the turn signal switch. You need to check the large orange wire and see if it is providing power to the left handlebar electrical control.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/03/18 at 13:11:36

Hi Mr. Dave.
Where is the large orange wire located?

Title: Re: Horn and Headlight is not working Help
Post by Dave on 05/03/18 at 14:07:09

It is inside the wiring harness that goes from the connector on the left side under the tank - up to the left electric control on the handle bar.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/03/18 at 16:54:17

I couldn't find any large orange wire under the gas tank so I was checking wire diagram for 2007-2009 at Technical section. I am not sure I am reading right but I can't see orange wire is directly going to horn, headlight, pass switches. And also I found high beam indicator isn't working(bulb is good I checked). So I checked 2004 diagram at tech section it looks like orange wire is connecting to connector then change to red/black and this red/black wire goes to horn, headlight, and pass switches. I am lost big time. Even if I found wire I don't know how to check if wire is good or bad. Right now I just want put it back together then ride only daytime and buy some wires and switch for horn so I can directly connect to battery. I don't want waste too much time looking for problems. I just want to ride. :'(

Title: Re: Horn and Headlight is not working Help
Post by batman on 05/03/18 at 22:32:56

You seem to be a bit lost when dealing with your wiring ,you need to seek some local help, or if you just want to ride leave the bike stock.

Title: Re: Horn and Headlight is not working Help
Post by kylejang on 05/04/18 at 18:45:03

Problem solved!!! I read wire diagram carefully found power is connect to starter switch so I opened up right handlebar and found problem. I fixed and cleaned now all working good. So problem was not from horn. Thank god, I actually about to open up all wire harness. Thank you everyone for reading and answering questions. Have a good weekend.