Motorcycle Repair: no headlight/etc., fuse holders, 750 honda


Question
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Followup To
Question -
Hi. I have a 1976 750 honda. I have no headlight power(lo or hi) and no starter. I can however kick start it. I've checked for obvious loose connections and have found nothing. HELP!
Thanks, Bill
Answer -
Bill, the right side starter/headlight switch is a known point of failure in these mid-70s machines. The switch has collapsed internally and apparently fails to function in either mode. Replace the switch assembly... $100 part new and it should fix your problems.
...Sorry, I should have mentioned that the previous owner already bypassed the starter switch. He wired a toggle switch that engages the starter in one direction and turns on the headlight in the other direction. He has this wired inside the headlight cup. I've checked that switch and it seems ok. To make things tougher, it has become a intermittent trouble. Ive tried to wiggle the wires thinking I have a lose connection but to no avail. When it does work. I get about 10.5 volts on the power lead. I've had the bike for 2 yrs and had no problem till now.  Thanks for your imput. It is greatly appreciated. Bill Runnells.  

Answer
Bill, the central source still has to be the switch. That is the only thing that is in common between the two circuits. You could check the ignition switch feed and the fuse holders, too. I would try a new toggle switch to be sure. If the switch wasn't rated for that much current, over time the switch contacts will eventually fry.

10.2 is kind of low for a 12v system, although it tends to dip when you turn on the ignition due to the light draw from the running lights, ignition, tail light, instrument lights, etc. Check the output when it is running to be sure you don't have charging system issues on top of the other problems.

Bill