2011 M696 Headlight Problems

[wiggsmeister]

Last night my headlight on my 2011 m696 decided to stop working at the end of a ride. Initially a fuse was blown (tail & brake light were out and the blinkers didn't work) so I replaced all the fuses on the side of the road. Everything else worked properly after that, besides the headlight which wouldn't come on with low beams or high beams.

The odd thing is that what I use the high beam trigger (does the same thing as flashing your high beams in a car) the high beams come on.

I'm thinking its just a wiring issue/broken connection since the light still lights up.

any tips would be appreciated!

[cyberswine]

Some people have reported relay issues on the new gens, the relay is tucked in behind the battery.  Most common problem is the now infamous white  headlight connector tucked under the left side handlebars.  Check that first!   Mine, and pictures I've seen posted from others, had at least one pin burned.  I ended up taking mine out and patching in some extra wire.

[wiggsmeister]

Great. now I have a much better idea of where to look. I'm pretty much a novice when it comes to these things so bear with me.

If the problem is the relay itself will i need to order a replacement part, and if it's the white headlight connector then i can just kind of jimmy the wiring and patch it together like you did, correct?
 

[Howie]

Since the passing function works the problem is either the relay or the headlight switch.  Still under warranty?

[jaxduc]

Most common problem is the now infamous white  headlight connector tucked under the left side handlebars. 

This.
I had the same headlight issues.
The problem (at least on my 696) was the white connector mentioned.

[alibaba]

Same same as JacDux   2009 696

[wiggsmeister]

I took some things apart today and replaced fuses again just to be sure, and unfortunately that yielded the same result as before.

There are two white connectors on the left side of the bike. One is behind the left fork and the other is attached to the bike's frame. Which one is the connector that's been causing the problems.

I would have posted the pictures I took but don't know how to post pics on this forum :/

[cyberswine]

The connector is the one mounted on a shiny metal bracket on the lower triple left side.
For the record, I took mine in last year under warranty and the dealer did half a job which lasted about a week.  I tried dielectric grease and tape but finally gave up.  After deleting the white connector I used spades for connectors and left the cable long enough I can drop the headlight on to the fender to change a bulb if needs be without having to untape and disconnect.

[wiggsmeister]

Right, that's what Im worried about with my dealer. I have to check to see if I'm still under warranty. I bought my bike used from the dealer in November 2011, but I'm not sure how my bike's being pre-owned effects the warranty.

So it sounds like you just ended up jimmying your connection to replace the connector, yes?

[Enzoman]

It's this one with the 4 prongs...

You can see the bottom left is discolored and a little burnt. Mine wasn't too badly fried so I took the connections out of the plug and cleaned them with emery cloth. The female pin was really loose fitting so I crimped it down a little and everything seems nice and tight now, but time will tell. I suggest taking the bracket off with the plug so it's easier to get access to it. Mine wasn't blowing any fuses but I can imagine if I let it go any longer eventually there would have been a short somewhere.

[wiggsmeister]

Ok perfect. Now I know exactly what to look for. Thanks for the pic, it was very helpful.

When i started the bike today, the headlight worked properly.. go figure. I definitely will need to get this permanently fixed since I don't want my headlight cutting out on me one night leaving me stranded again..

[scooterd145]

I had the same issue with the white connector, It was intermittant at first (sounds like yours is too) but eventually burned enough on a night ride that it died. I did like others and just deleted the connector and hard wired it together.

[wiggsmeister]

The female connector is fried. Luckily I' m still under warranty (until April 29th this year!). I took it to the dealer today and he said to bring it back tomorrow morning (or this morning now) and He'll replace it all for free!

stoked!

thanks again for all the input everyone

[JamMad]

Surprisingly common... although mine just stopped working without actually frying.

I also found it a NIGHTMARE to separate, but in trying to... I've fixed the light.

Fingers crossed it lasts until a much better replacement "4 pin waterproof connector kit" arrives from eBay.

Thanks to the forum solving my problem, I've just joined.... so THANKS!

If yours was replaced under warranty you might want to double check the replacement... if it's the same, it's only a matter of time before it goes again; the position makes it liable to failure as the female 'cup' connector faces up, so fills with water easily.

[danaid]

 I used this place for my replacement connecter , http://www.cycleterminal.com/index.html

Emailed the company and they reccemended a heavy duty connecter and  the tools needed