Motorcycle Repair: 1996 Virago Headlight malfunction, yamaha virago 535, dielectric grease

Question
I purchased recently a used 1996 Yamaha Virago 535 and am generally pleased with the bike. However, upon occasion, the headlight either fails to turn on when starting the bike, or cuts off after the bike is running. I have checked for loose connections into the headlamp and all appears ok. What could be causing this and whatcan I do to check for malfunctions?

Answer
Hi Charlie,

1. Trace the headlight circuit and inspect all related wiring and connectors for loose fit and corrosion. All metal connectors must be clean and tight. Purchase the Service Manual for wiring diagrams.

2. Disassemble the control assembly that houses the starter button. Examine the starter button contacts for corrosion.

(When the starter button is pressed, the headlight goes out to use maximum electrical current for starting the engine. The headlight is part of the starter circuit.)

Review the following information and keep me advised.

Respectfully,
Mark Shively



Dielectric Grease Therapy

Here's a fairly quick and inexpensive way of preventing electrical problems and other miscellaneous diagnostic codes on your motorcycle.

Water is a great electricity conductor. Sometimes, water can find its way into a connector producing a temporary short circuit which will then give an error code to your computers. Dielectric grease prevents water shorting at connectors. Also prevents corrosion formation on connectors.

A loose connector doesn't make a good conductor and may produce heat which can melt plugs and connectors. This is the main cause of regulator/rectifier failure.

Buy a tube of silicone dielectric grease and go through the entire wiring on your motorcycle. Work dielectric grease into each connector. All wire connectors should be serviced for best protection. Removing the tank and bodywork may be necessary in some cases, but its well worth it. Dielectric grease will get rid of the problems, or at least help prevent them.

Afterwards, you shouldn't get false error diagnostic codes just because you simply washed your pride and joy.
You may discover loose connectors that could have been troublesome if left unattended.