2001 RSV Mille dipped and main not working

Hi all I'm new on here so please be gentle!!!

I have purchased the other day said bike for a reasonable £1800.

Only problem I saw was the main beam/dip would not work on the switch but only with the flash/pass/lap button.

So I checked the fuse....ok
Switched the 3 relays around to see if it would get the switch working....no such luck:angry

So took the front of the fairing off to see and it loooks like someone has been at the wires ...........there is 4 wires strapped together 3 solid green and 1 white/green that come from the left handlebar switch and were twisted together(bodged) to a thickish bright green wire that goes to the loom at the back of the clocks. Also some1 had bridged a piece of wire on the headlight connectors from the sidelight terminal to dipped beam to make it work..............


Ok so ignition on not started flick the light switch and I got 2 rear lights and 1 front sidelight and clock lights are on.
Engine running 2 rear lights, clock lights, sidelight and dipped on (with the bridged connection) so obvious the hi/lo beam switch won't work cos its not connected!!

anyone got any ideas on how to fathom out this mess???
can post some pics if this will make it any clearer

a puzzled new rsv owner

ok here are 2 pics of the what looks like bodge up central the 4 green wires are coming from the left hand switchgear all were twisted together to the thicker dark green wire that goes up to the loom behind the clocks



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And here is pic of the bridged connector at the lighting loom so the dipped beam will always be on as its connect to the front sidelight god what bodgers people are!!!!!
Hope these pics help as I can't seem to find a wiring diagram for the bike



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Sorry forgot to mention when the thick green wire is disconnected from the 4 wires crimped together as in the 2 pics there is no lights at all not even on the dash so I guess this is the main light feed wire??

Here is a pic of said bike from the ebay listing

seller if you read this forum you know who you are..... I asked if there was anything wrong with this bike to which he replied categorically 'NO' but since trying to ring has said well why would you want to ride this bike at night anyway....what a to**er......:angry

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Cheers for ur input lonner ....but yes I can switch the lights off and on with the left bar switch but only cos the dipped beam has been connected to the sidelight feed by that u-peice in pics 3+4 ......yes my main concern is the dip/main swith not working as it won't pass mot wiothout this, but if I take that u-peice out I got no front lights at all... except sidelight.......aaaarrrgghhh ok does any1 here on the forum have a 2001 standardrsv mille wiring diagram??? or mebe a link to 1?? would be much appreciated

ok thanks got the wiring loom link.........much appreciated but when observing the wiring diagram cannot seem to find these wire colours coming from the handlebar switch??????
Looking at my wires there are 2 lighter green, 1 darker green and a white/green stripe all pinned together which is not even on there??

lonner said:

well i think this is what's wrong ie someone has made it so you can switch OFF the lights and they were meant to be on with ignition.
all the handlebar switch does is allow high or low .

so if you undo whats been bodged you will have the fix

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I think the 4 wires crimped together should be attatched to wires coming from the other end of the plug.............but cannot see any just the 1 large green wire.
I have noticed on the wiring diagram a red/blue wire that goes to the negative battery terminal so will check that today but if the sidelights are working surely its ok??

cowelly said:

I have a spare high/low left handlebar switch if you want it, give me a shout

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Ok cool thanks bud have pm'd ya............

Ok I took off the right hand switch gear its a 3 postion light switch by the way for a better look this evening and still can't see whats happened here............wires at the switch look ok if a bit crushed...... but there where the four wires are crimped together there is no other wires that lead to them form the plug end ...............anyone know if this is how its supposed to be,..like this... the crimp just dosn't look like a factory fitting for my liking but it is holding the off position light wire green/black+main headlight wire and also 2 light green which from what I can see in the switch housing 1 goes to the pass light switch and the other green goes to the horn!!!!!!!
Indeed what lonner said yesterday this looks like it could have been wired to an alarm at some point as all these wires put together would obvious make the headlights/horn go off............



What looks 2 wires plug end is actually a shadow!!

my only observation is the green/black wire that goes to off position of the light switch and so is connected to the 3 others but if I disconnected this wire from the others where does it go????? any suggestions could be fruitful :banghead

Any1 got a 98 to 02 left hand 3 position light switch cluster in GWO with all wires and plug in good nick knocking around.....Cowelly has offered me 1 which I'm gonna go for but i need sommat quick so I can sort and ride this thang!!!!!!!!!!!

lonner said:

having looked at this wiring in the haynes the green wires are the power feed for the light switch lap switch horn and the turn switch.

so as its a common live which has a multi point join then one wire at the loom connection plug for the feed.

so if all the above switches are not working then simply rejoin that cluster and shrink rap or tape up and see if that solves it .

also check the earth is good .

also you can check the single wire for feed before rejoining just to make sure you have a feed.

all i can offer really without it being in front of me (so much easier when its under your nose) lol

hth

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Is the switch earthed on the bars through the locating pin as its seems a bit corroded??

FIXED!!!!...........Well a couple of problems anyway!

First of all I woukd like to say a very big thankyou to :thumbup Cowelly :thumbup diamond geezer who came up trumps when it mattered.......................

Ok been busy in the garage this evening firstly fitted the light switch Cowelly sent me and hey presto I have lights again!!!!!!!!!!!.................but this switch is the new type so lights come on with the ignition which I don't want as it puts to much drain on the small battery............this has probably been documented to death on here but here goes anyway.
Firstly I modded the light switch, soldering a bridge wire between dipped and main beam shown in the mods section for all 3 lights to come on together





I wanted a separate switch to be able to turn the dipped beam off independantly when the ignition is turned on but to retain the front parking light and rear lights on constant as I have changed them to led bulbs so power consumption is extremely low.
I did read somewhere can't remember where now some1 wiring a toggle switch up so decided on this here goes.............
first off drill 11mm hole on the clock cover trim......attatched 2 large core cables heavier guage than lighting loom to a heavy duty toggle switch then heat shrinked the connection so no worries about a short
VOILA

[video]http://imageshack.us/clip/my-videos/151/a91.mp4/[/video]





Ok run the 2 cables form the switch down the sidee of the clocks and leave enough spare to be able to connect to the light side of the lighting loom then cut your feed to the dipped beam and wire to the toggle switch (with insulated connectors) here is pic of the wiring in situ but I taped & tidied it all up after I took this


Now I got my headlights on a separate switch so cutting the battery some slack when starting.........hope this comes in handy for any1 wanting to do this mod its actually very easy and can be done in an hour if you got all the right tools..............:biggrin