hey dear FJR owners.. you're my last hope.
i have an electrical issue I cannot resolve. here is the story:
I had to change nose/headlamp/forks of my GenII after an accident. I was able to put all back together to a nice state. While I was waiting for the last parts I tested the electrical system and all seemed to be working fine.
then about three weeks ago the headlamp decided not to turn on. This is what I've done so far:
Checked the bulbs (tester for conductivity), tried new ones JIC
Checked the 25A fuse (same as above)
Uninstalled the nose to access all the relays:
there are two relays on left of the speedometer. one is for hazards, other is either dimmer or on/off headlamp. tested that one and it works (following directions on yamaha mechanic manual)
in front of the battery there are other three relays: fan motor, headlamp dimmer or on/off and a third line I can't remember. Tested all of them and all work.
I entered the diagnostic menu and under d52 trouble light goes on/off 5 times, I hear clicking but still no light.
I'm running low on ideas. There are still two things that I have doubts about:
when I checked the voltage at the light bulb socket, i get a reading of around 6V (shouldn't it be 12V?), second thing is that larger relay under the headlight (picture below 5VK-81950-30-00), I can't test it because my tester won't get in the small openings. I know it's for other functions such as fuel pump, main switch etc. Does it have anything to do with headlamps? I could try to buy a new one just in case. I've visually checked all the wires/connections and I can't see anything obviously wrong. Any other things you can think of that I might have missed?
Without lights I can't get an MOT, therefore no insurance, therefore I can't ride it to a mechanic. It's diving me insane!
Any help will be rewarded with a pint, shipped right to your door!

Attached Images

File Type: jpg	IMG_3825.jpg (232.1 KB, 48 views)
File Type: jpg	IMG_3826.jpg (146.1 KB, 28 views)

Hi,
Instead of checking the voltage across the headlight socket terminals, take the -ve lead of the meter back to the neutral of the battery.
(bypass the bikes neutral wiring)

Sounds like it may be a spider fault, something not right with the neutral wiring or connector blocks some where.



Does the windscreen motor work ?
Do both indicators work properly and not 1/2 brightness

Could be terminal 4 on the S7 or terminal 1 on / or the wiring to S6

The S6 spider is a known problem.

My friend had a similar problem on his gen1, we found that on the wiring diagram there are 2 relays for the lights numbered 55 and 56. 55 is connected to the cpu via a yellow/blue wire, we worked out that power from the cpu switches the relay 55 allowing power to flow through the relay to relay 56, this was the relay that powered the lights, now here is the bad news, nothing shown voltage wise from the cpu, our cure was to change the cpu but we did prove it was faulty by applying a voltage to the yellow/blue wire and the lights worked, hopefully yours is something else.

these are two very good leads, i didn't think about
definitely will give them a shot next weekend.

thanks for now, will keep you posted

when you split connectors or put relays back give them a squirt with ACF 50, or similar.
On my early gen 2 there was a relay under the headlamp and a connection got corroded and failed to work, I think that it affected the ABS, but a quick squirt fixed it. Interestingly on the later gen 2 that relay was moved.

Guys I'm stuck!I've tried everything.. I cannot find the issue. This is really frustrating because it's something I can't fix after doing things much more complicated like changing forks and all the plastics/headlight etc. Since I Cant get MOT or insurance I can't even drive it to a mechanic, and regardless I really don't trust them!
Any one in north london that feels like helping out a fellow FJRer? I need someone with more expertise then me to bounce off ideas and help me find the problem. On weekends I'm home but if you can during the week I could take the day off. I would be super duper grateful. I wouldn't mind paying for your fuel to get here and food.

As you're in London, you could try asking for help from www.londonbikers.com, they should be able to point you in the direction of someone reliable with electrickery.

An other option might be to rig up a temporary supply to the lights, just to pass the test.

Got the impression that you are new to the UK, so might not be aware of some of the finer points of vehicle testing. Having had a succession of rather old and delapidated vehicles (still got one on the drive ) AFAIK it is legal to use a motor vehicle without a current entry in the MOT database, as long as you are travelling to a place where it has a prebooked MOT test. Still need insurance though, but in my experience the insurance companies stipulation was that it must be road legal, and in this case as it was a legal journey you would be covered. Probably best to check with them first though, rather than trusting the word of some random bloke off the internet.

thank you marsh man, i've posted on london biker as well. hopefully someone will feel like helping!
cheers

Can be a bit boisterous on there, but when I was commuting in to London everyday, they would know who to get in touch with to help sort out any problems. Possibly even including 'sorting out' problem makers as well Read some of the stolen bike threads and you may not be sleeping so easily if you have to park your bike in the road

I use VIAGRA.....my headlight works fine!