I took my bike in to have its Manx Test (bit like an MOT) on Thursday, which it has to have before it can be registered on the Isle of Man. When it came to the headlight test, turned the lights on headlight popped up and light came on, but it was shining too low, so I turned the adjuster knob under the fairing which lifts the light, after a few turns, the knob spins back and the headlight shuts itself down. Try again and the same thing happens, then the headlight switches on, but it doesn't come up. Now sometimes it will come up and other times wont.
I was told when I bought the bike that it had been fitted with the replacement box of tricks supplied by the club?. Before I take the fairing off and look further into this has anyone any idea what is going on?
Popup headlight
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johnr
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Re: Popup headlight
has your slight adjustment not moved the lens so it is now sticking on its way up or down? is the servo trying to lift it when you switch?
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fossie
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Re: Popup headlight
You are turning the wrong knob sir!!!! You are twisting the RED knob!!!!!
The headlamp adjuster knob is BLACK and attached to the rim of the headlamp .
( bottom left.)
The one you are twisting only sets the MOTOR and is a safety feature so you can get the light up if te motor is not working. If the motor works once the contacts get past the blank area it will connect and send the motor on the next cycle. which means all is well in that department.
The headlamp adjuster knob is BLACK and attached to the rim of the headlamp .
( bottom left.)
The one you are twisting only sets the MOTOR and is a safety feature so you can get the light up if te motor is not working. If the motor works once the contacts get past the blank area it will connect and send the motor on the next cycle. which means all is well in that department.
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Ash
Re: Popup headlight
Fossie, that's the sort of answer I want to read, not having a handbook didn't help.
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Ash
Re: Popup headlight
Took the fairing off this evening to have a better look. The control unit which I was told was a replacement looks original to me. I think it must have a few iffy connections, moving the connector either makes the light popup up or the lights come on. Cleaned the connectors and given them a spray of WD40. Took the top of the control unit off, but underneath its filled with some type of resin.
Switching the headlights on, sometimes it will come up with the light switching on or maybe not and sometimes it wont come up and the light switches on.
Anyone got any ideas?
Switching the headlights on, sometimes it will come up with the light switching on or maybe not and sometimes it wont come up and the light switches on.
Anyone got any ideas?
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fossie
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Re: Popup headlight
Firstly I will say that you seem to have the original box there as ours are not in the black casing. 
I did take some photo's of our replacement boxes but the pictures have been eaten by my PC. So I will do them again later.
The original boxes are resin filled and it took us many attempts to dissolve it, however most of the componants in it were now superseeded, so we made our own using relays instead of the conveluted way it operated in 1983.!
OK your problem is most likely control box(module). As you light works, but the power isn't switching to the motor.
This is how it works
ON power to motor, when at top, power goes to headlamp.
OFF- light off so power goes to motor until parked.
Essentially it is a windscreen wiper motor idea , in that it is a disc with contacts and a break, which is lined up with the down or up position.
It may be an idea to lube the pivot arm as any resistance may stop the arm moving but the disc is still rotating. ( straws -clutching= false hope or no hope.)
Was it working ok before you twirled the wrong knob?
From whom did you purchase the bike, it may help as we rewired an Aussie one to suit a normal box, which was just a case of moving the spades in the loom, you never know!
Heres a couple of pics of the original boxes. Note 2 types,
Different pins missing.
We will be doing a section for pop ups soon so I will post we have on the replacement boxes. Everything on there so as not to clog up all threads .
I did take some photo's of our replacement boxes but the pictures have been eaten by my PC. So I will do them again later.
The original boxes are resin filled and it took us many attempts to dissolve it, however most of the componants in it were now superseeded, so we made our own using relays instead of the conveluted way it operated in 1983.!
OK your problem is most likely control box(module). As you light works, but the power isn't switching to the motor.
This is how it works
ON power to motor, when at top, power goes to headlamp.
OFF- light off so power goes to motor until parked.
Essentially it is a windscreen wiper motor idea , in that it is a disc with contacts and a break, which is lined up with the down or up position.
It may be an idea to lube the pivot arm as any resistance may stop the arm moving but the disc is still rotating. ( straws -clutching= false hope or no hope.)
Was it working ok before you twirled the wrong knob?
From whom did you purchase the bike, it may help as we rewired an Aussie one to suit a normal box, which was just a case of moving the spades in the loom, you never know!
Heres a couple of pics of the original boxes. Note 2 types,
Different pins missing.
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Ash
Re: Popup headlight
Fossil, thanks for the detailed reply.
It was a bit problematic before I turned the knob. I got the bike from one of the members here 'Uber Pikey (Curt)" looking at the loom near to the black box it does look as if it has been cut and repaired at some time. I have noticed that when it does go up with the light on there's a ticking noise coming from the control box.
Just tried it now, light came on, but didn't go up moved the block connector going into the control unit, light goes up and stays on, ticking noise.
Are replacement boxes available still? The original ones from Suzuki seem to be but are around £165.00 plus VAT.
It was a bit problematic before I turned the knob. I got the bike from one of the members here 'Uber Pikey (Curt)" looking at the loom near to the black box it does look as if it has been cut and repaired at some time. I have noticed that when it does go up with the light on there's a ticking noise coming from the control box.
Just tried it now, light came on, but didn't go up moved the block connector going into the control unit, light goes up and stays on, ticking noise.
Are replacement boxes available still? The original ones from Suzuki seem to be but are around £165.00 plus VAT.
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fossie
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Re: Popup headlight
Sorry about delay in posting this but Kat HQ has now moved upstairs, so there was a delay in the ................AW bolloix I'm a lazy b*gger! 
Anyway we have 2 replacement boxes left.They are not in the black plastic box as the original, because they don't need to be but you could empty yours and fit the replacement in, although you will need to cut 2 holes for the relays to protroud.
However no one we see it any way.
We did fit 2 led's one green one red , one to show power to the board and one to show power to the motor( it comes on when the motor is in operation, or should be .) As a sort of check circuit.
Price ; up to now we have only sold to club members But £55 incl p&P seems fair.
Our box showing 2 leds.
underside and mounting screws.
This is whats Under the resin
underside of the underside!
Anyway we have 2 replacement boxes left.They are not in the black plastic box as the original, because they don't need to be but you could empty yours and fit the replacement in, although you will need to cut 2 holes for the relays to protroud.
However no one we see it any way.
We did fit 2 led's one green one red , one to show power to the board and one to show power to the motor( it comes on when the motor is in operation, or should be .) As a sort of check circuit.
Price ; up to now we have only sold to club members But £55 incl p&P seems fair.
