electrical issues.

[money]

Hi everyone, I am new to this board and hoping I could maybe get some help. A little background---I am almost done with my 650 and it is a bit different than the usual.  I have moved the key switched to under the frame and also put a 66 Honda headlight bucket on the front so I could incorporate the headlight, speedo, and horn all in that bucket---plus I have the blinkers coming off the sides as well.  So, I eliminated the tach and also the light system in the middle where the key was before.  So, here is what I have currently, it is all wired but I have two wires that I don't have homes for.  One is a light green that I found out is the RLU and I am eliminating that and wiring in a top little light to show the bike is charging with the help of a mod from another forum.  So, that light green wire has a home.  But I have a white wire with a green stripe that does nothing.  Will this wire have something to do with my blinkers and the fact that they stay lit when I turn them on and they do not blink?   And no, they are not LED's.  I turned the headlight on and success!!  It worked until I turned it off and then back on again and NOTHING---and I didn't do anything and no it did not burn out---the filament is there.  I was thinking I burnt out the RLU so that is why I eliminated it but I still can't get the headlight back on.  Did I burn something else out per chance?  The little lights on the top still work and so do the blinkers, although they still don't blink.  WTH??

I am going to add pictures if I can figure it out that is.  LOL

Thanks for everyone's help.

Jeff

[jetmechmarty]

Jeff failed to say what bike. I believe he has a XS650D. Welcome aboard, Jeff!

[money]

You are correct Marty--650D.

Jeff

[xsleo]

On your turn signals not flashing, it sounds like you are using the stock flasher. If so those signals you have use 23 watt bulbs. The stock flasher needs 27 watt bulbs to flash. Replace the flasher with most any non load sensitive two prong flasher from the parts store. I think 533 is the number.
When you plug the two prong flasher into the tree prong socket be sure it plugs into the socket so it plugs into the brown and brown white wires.
The third wire Is a green/yellow and goes to the self canceler. The self canceler can be chucked in the trash. They don't function well.
On your RLU when you remove it you need to jumper the blue/black wire to the yellow/blue wire. This bypasses the RLU to send power from the on/off switch to the dimmer switch.
If it worked once but not now I would check all the connections from the headlight fuse to the headlight. Ah, speaking of fuses, are you using the stock fuse holders? If so that could be the problem. Round glass fuses were crap 30 plus years ago and have gotten worse since then.
Upgrading to modern blade type fuses will help greatly.
Leo