Headlight Issue

[Zeb]

I am in the process of replacing my whole front end on my 08 (hit a deer).  The right headlight housing was smashed up, so I found a used 08 headlight housing to replace it.  pulled the old headlight housing off yesterday and then plugged the used one in and the lights do not work.  Am I missing something?  Fuse was blown so I replaced it and they still do not turn on.

Any feedback would be appreciated!

 

[BigOgre]

I guess I get to ask it first: Did you confirm all the bulbs are good?  FJRs are notorious for having both bulbs burn out within a short period of time from each other.  Add in shipping, bouncing around, etc, etc.

 

[Zeb]

That's my next move.  Just thought I'd ask first to see if I am missing something other than that...

 

[Niehart]

And the bike has to be running for headlight power.

 

[RossKean]

And the bike has to be running for headlight power.

Good point! 

 

[Zeb]

Yep.  Started it up multiple times and unplugged and replugged lights and had no luck with headlights coming on.

 

[mcatrophy]

Headlight relay(s) broken? I think they are mounted somewhere in front of the battery. Since it was the right side damaged, could that area have been affected?

 

[pierreroyoldtimer]

I have been trough a similar problem with my 2005. I found that, for no apparent reason, the headlight fuse prongs had a slight discoloration, wish was oxydation. I cleaned them with a very fine grit sandpaper, (600-800, you can also replace the fuse even if it test good), put some dielectrical grease and they started to work normally again and never failed in 15,000 miles.

 

[Zeb]

Sorry, it was the left-front side of the bike that got smashed so probably didn't mess up the relay (if its on the battery side).

I'll try cleaning the fuse prongs. 

 

[mcatrophy]

There are two headlight relays, on-off and dip. One of them is on the left side, look at this diagram (this of an '06, but I think it's the same as an '08).

Item 11 is the dipping relay.

(Click on image for larger view)