1980 spitfire light issues

[cjhi]

hey there. just got a 1980 spitfire recently (first sled yahoo) got it running really nicely but some minor issues i have to deal with.

the headlight has no power to it, the high/low switch was wrapped in electrical tape for an unknown reason. i removed the tape and neither position of the switch shows power right at the headlight plug there is another little plug 4pin looks like that i have no idea what is for id guess guages? (this machine has none) but anyways the 4 pin plug has power registering
anyways not knowing these machines im not sure what to check to see where the issue is. any advice on that subject would be perfect to get me going.

other issue i am having is the recoil was off the sled and torn apart when i purchased it. one of the tabs was missing. located one at a local store and foolish me in the process of putting the recoil together broke the spring. checked around cant find any locally (havent checked online yet) one of the local mechanics led me to believe that there is some sort of universal spring that would work? my mind says thats possible but i want to be sure before i drop the money on the kit and find out it wont work.

thanks in advance
-Colt

[JDT]

You never mentioned the brake/tail light not working so I assume it is.

The Yellow wire supplies power to the dimmer switch.

If you have power there than the switch is either bad or the harness to the headlight has a problem.

If you do not have power at the switch than you have a connector/harness issue between the handle bars and the dash.

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You actually broke the recoil spring or it just went boing and unwound in a twisted pile?

Best bet may be to find a good used recoil assy.
I am sure one of the guys on here that deals in a lot of used parts can set you up.

[cjhi]

ah appologies not mentioning the tail light. the previous owner removed it and im unsure if the wires are there or gone. so i have to find one somewhere someday or rig something up. to be honest this machine isnt the prettiest but it runs well

if memory serves correctly (havent looked at the harness in a few days) the headlight plug has a red green and black wire to it. the black one crosses over to the 4 pin plug i mentioned earlier and then back into the harness. the red and green im sure will go to the dimmer switch. i want to say that the 4 pin plug has the black wire but then 3 yellow wires to it... but as i suspect that 4 pin plug is for a guage or something. im trying to remember.

now to your yellow wire. just to clarify (im still waking up after a long night sorry) i assume you mean the dimmer switch should have a yellow leading into it and i should check there for power? if so i have not checked that one yet.
the yellow i did check that had voltage was in that 4 pin plug.

would it assist if i took a picture and posted it? im afraid i might not be explaining myself very well.

the spring itself broke yes. my fault. if someone could set me up with a recoil or point me in a good direction im all for it.

[JDT]

You should post in the classifieds section for a recoil assy, taillght assy and harness that goes to the back and a dimmer switch.

It is possible that the reason everything is taped up is someone modified or replaced the harness going to the handlebars.
But either way there has to be power to one of the three wires at the dimmer switch whenever the engine is running.

Sometime with an ohm meter and careful visual inspection of your wiring harness will help identify your problems.
Keep in mind that contact from any hot wire to any ground anywhere on the sled will take out the lights.

Just a couple of things to look for...

Connectors that have been cut off leaving exposed wires that can contact a ground.
Wires rubbed bare and grounded out under the seat or near any moving part like the jackshaft, brake disc, clutch ect.
Harness making contact with muffler/exhaust melting the insulation and shorting out.
Bad terminal inside a connector at the headlight.
Make sure both elements in your headlight are actually good.

[cjhi]

not a bad idea at all posting in classifieds thank you.

i found myself a wiring map and in a bit im going to go out heat up the garage and try to decipher things. hopefully its something as simple as a broken wire. i plan to do a continuity test down the lines to check for broken and a visual inspection for any where the wires outer protective coating has been worn away. ill post back what my discoveries are once i know. thanks for the advice its much appreciated.

[cjhi]

found my problem. previous owner had cut off the harness for the tail lights and the routing for the power is to tail light then back to the dimmer switch and then headlight.

previous owner having cut the harness i had no power at all anywhere in the headlight circuit. i opened up the wires and spliced together the two yellow in the tail light harness and boom full power! headlamps working. its a lovely day now i dont have to get home before dark if i want. (tried once duct taping a good flashlight to the hood failed miserably)

one problem down more to go. discovering more as i go to.

downside where i live not enough snow to do as much riding yet as i want

[JDT]

Anytime I see a harness that has been messed with I always suspect that is going to be an issue.

But you should get a brake/taillight put back on for safety reasons alone.
Never mind the fact that it attracts the attention of LEO.

Lack of snow is a concern here in SD also.

[cjhi]

i plan to get a proper tail light on the machine but i will take my time and find a oem one. tonight project becomes the recoil. found a spring for it today so hopefully this one doesnt break in my hands to