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General Category >> Rubber Side Down! >> 2006Boulevard / headlight&horn disappearing trick[ch129300]
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Message started by Thekillerchill on 04/27/20 at 01:07:21

Title: 2006Boulevard / headlight&horn disappearing trick[ch129300]
Post by Thekillerchill on 04/27/20 at 01:07:21

Angela here !
Bike: 2006 boulevard -s40
My mechanic experience: proud I changed out my battery by myself.
Need help: headlight and bulb would go in and out / now they just quit
What I tried:use to tickle the wires on the right and that use to help, DOESNT respond to that anymore , new bulb , not it. Don’t know which relay it is , also I was confused about one post about a connector.
I downloaded the wire diagram but it’s Morse code.
Please help, in other news! I switched out the the faulty petcock as suggested ! Thanks everyone!
Wahooo!!!!!

Title: Re: 2006Boulevard / headlight&horn disappearin
Post by Gary_in_NJ on 04/27/20 at 04:09:04

There is a connector from the main wire harness to the H4 headlight plug. It may be loose. But since you mentioned that both the headlight and the horn have both failed, that indicates that the problem lies in the left handlebar control or its connector. If you follow the wire coming from the handlebar control you will see that there is a connector that joins this control switch to the main harness. Disconnect this and check it for signs of corrosion. When reconnecting it, spray the contacts with contact cleaner. This should cure the issue. If the bike is stored outside (or has in the past) there is a possibility the the corrosion is in the control switch. It’s less likely given that you’ve lost both the light and horn.

Title: Re: 2006Boulevard / headlight&horn disappearin
Post by batman on 04/27/20 at 09:20:43

the largest connector on the bike sits in the area just above the spark coil (with about 8-10 wires depending on year) this is the one you need to check to be sure it's both clean and tight , be especially observant of the black wire with white strip , that color is always used as. neg. -ground wire and in the case of the bike is the only thing that the headlight , front running lights and the horn have in common they all link up and pass through that connector. good luck

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by justin_o_guy2 on 04/27/20 at 09:35:15

Disconnecting and reconnecting several times can accomplish Some cleaning. Using dielectric grease protects from corrosion,, LIke Brylcreme, a Little dab will do ya

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 05/26/20 at 22:00:52

Ok .... I have been at the shop 2 days soo far . I have located the box. When you mean connect and disconnect , does that mean unplug and plug it back in?

Also, any one interested in just coming to California and helping me , I was soo angry at my motorcycle I almost cursed at her .

Uuhhhhhhh

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 05/26/20 at 22:01:33

Face time mechanic help ??? I’m soooo lost rn .

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Gary_in_NJ on 05/27/20 at 04:04:17

Yes, if you have located the connector, simply disconnect and reconnect it several times. If you want to do something more useful, while apart spray it with contact cleaner & lubricant. If one connector has corrosion, they all in their way, so I’d spray them all.

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 05/27/20 at 16:43:37

So we stuck the voltage meter in the connector and it reads no voltage

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Gary_in_NJ on 05/27/20 at 18:00:22

The orange wires carry the current to the connector. Did any of the orange wires show voltage?

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 05/27/20 at 21:07:24

I just bought a lil tool pack from the mechanic and picked up the creem at Walmart. Im a pro now at removing my seat and tank. I’m going smoke a spliff and see where this takes me . I believe the mechanic has given up on my Halah( my bikes name ).

Also- funny story.

The other day at the shop , the temp was like 103 (Stockton, California)
So I figured I’d get us a drink before we got started . I ride over to the liquor store and my bike starts to stop running. I end up pushing the bike back to the shop 2/3/4 blocks . When I get to the shop , mechanic says :
Would have helped if you put the bike back on fuel. Needless to say I needed a ten minute breather.
Apparently he flipped he switch over before he realized I was leaving , forgot to tell me .

And so now i am proficient at checking that.

;D

Lastly, I need new tires and breaks .

2006 boulevard s40.

Any suggestions before I buy it from the shop?

And thanks sooo much, I really appreciate all your help!

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 05/28/20 at 01:38:02

I found it !
It looks melted in 2 spots, I imagine the head light and horn
I wish photos were easier to post here,
There was a fine moment when I found the spot that made my light beam.

Anyway, does this mean I need a new connector block?

And where is a suggested site/ part number ?

Lastly-
Do I just cut um back and reconnect* them?

* idk how to do that yet .... :)

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by justin_o_guy2 on 05/28/20 at 07:54:43

Pictures would help, Good on ya for findin it

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by verslagen1 on 05/28/20 at 08:01:16

If the underlying wire is ok, you can just put shrink wrap over the melted parts.
But if the wire is burnt, better to replace. Cut and splice or search for a used part on ebay.
without seeing it, I don't know if it's repairable or if you can do it.

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 06/01/20 at 22:39:08

I did it. I clipped the two burned wires and soldered them together , I tried to use the lil straw plastic melting tho ha but I was horrible at it and just used some electrical tape. So far soo good.

I don’t feel like Cinderella anymore .
Thanks soo much for all of your help.

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 06/01/20 at 22:45:12

Oooohh

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 06/01/20 at 22:46:36

Solder time

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by justin_o_guy2 on 06/02/20 at 06:57:56

I havent seen a Big Weller designed like that in years.. Thats what mine looks like,but the last time I was lookin aroound, theyd changed the shape to a flat sided thing..

Title: Re: 2006Boulevard / headlight&horn disappearin
Post by Thekillerchill on 06/02/20 at 08:14:01

Yeah - I got the flat one too from Lowe’s . Luckily I have a friend who buys random nuts all day , so she brought over that guy. He worked significantly better .

So the connector was fried in two spots so I removed them from the box and connected them.
I am not sure this is a long term fix of if there was a bigger issue because it was fried in the first place.

Anyway- first time soldering job. I got one pregnant line and the other came out pretty smooth. There’s just not soo much wire to work with.

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 06/02/20 at 08:16:18

This is it

Title: Re: 2006Boulevard / headlight&horn disappearin
Post by Gary_in_NJ on 06/02/20 at 09:28:51

There's your problem. Over current heat damage.

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by Thekillerchill on 06/02/20 at 13:16:31

So what do I need to do to fix it fix it ?

Title: Re: 2006Boulevard / headlight&horn disappearing tr
Post by justin_o_guy2 on 06/02/20 at 13:24:29

IDK exactly what wires those are, what loads they carry, but you could get bullet connectors and pus a wire on the wires that are fried and jumper aroud the connector.
What does it plug into?