Re: 2001 CBR 929RR headlight problem
This appears to be an old post, but I have the same problem with my headlight. Dim was not working. Brights and everything else work. I opened the starter housing and saw one wire disconnected. Touching it back to a connector turned the headlight on. Soldering was done. However, riding for about 10 miles and headlight went off. Wire is once again disconnected. Soldering was done again, and once again after a short ride it gets disconnected.
I took the the whole housing off and cleaned all prior soldering to make sure nothing is touching the other wire connections. Soldered it again making sure no solder is touching any other connecting point. Tested continuity on both ends of the harness. Everything seemed to be working. Connected the harness, and the light wasn't working, so i fiddled with the headlight connected, and the headlight came on. I did notice that all the soldered points at the the started switch get pretty hot. The same hotness as when I was soldering the wire as the wire itself was getting hot.
So my guess is that that hot temperature dislodges the wire from its soldered connection. The other ones seems to be holding up fine even though they run hot as well.
The question is, is it normal for those wires to run a bit hot or is there a short somewhere that makes it run hot? Could it be the time of solder used that is not withstanding the heat if the the wire's temperature is supposed to run a hot. However, my guess that it is probably not normal for it to be hot.
The only things that happened prior to it. Rear undertail light was switched. I didn't do the wiring. Everything seemed fine after that. Then I changed the right handlebar and in the process got that wire mentioned above to disconnect from the its soldering. Soldering was done and that's when I had problems even with the charging system. Seemed as my battery died one after another. I did some tests and changed the stator and rectifier after which multi meter was showing a good 13-14 Volt charge while bike was under load. However, after a few months new battery once again was dead and would not hold charge. I had it on a trickle charge for two days and it never stopped charging (flashing light becomes solid when it is complete on other batteries.) So that is when I took the whole wire harness off to make sure soldering was clean and proper. and noticed that it was still hot as i found out prior to that.
Shouldn't be normal to run hot on the wires, right? Perhaps it is the harness? I used multi meter on ever connection individually on that harness checking continuity. None showed any continuity more than once per each connection.
Any help of where to look next would be greatly appreciated.