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D7 Headlight.
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Geoffrey25
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January 4, 2020 - 8:44 pm
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Hi all my d7headlight has stopped working but the tail light is still working,all wires in head light are all ok and all earth connections are ok.I did h as 've a look at the dip switch and on inspection there was some corrosion I cleaned off what I could get at and put it back together.Now I can get a faint glimmer of light from headlight bulb but no more and nothing on low beam so now I am thinking it is the dip switch itself has anyone had a similar problem many thanks  Joe.

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NeilB
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January 5, 2020 - 10:35 am
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Is the bike still 6v +ive earth, and is it the battery or direct lighting model?

First thought is test resistances, not like there are many wires on our bikes

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Geoffrey25
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January 5, 2020 - 11:14 am
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Hi it is direct lighting twin switch d7model it is 6 volt+earth I have tested the wires and am getting just about 6 Volts most of them the horn has also stopped working witch is pointing me towards needing a new handle bar dip /horn switch.

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Stoo63
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January 5, 2020 - 11:39 am
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Maybe try taking the switch apart and bypassing it..... These wee things are a nuisance!

'52 D1 direct lighting plunger, '58 Square Four (project), '59 D1 direct lighting plunger,  '59 Tiger Cub, '60 5TA,  '76 FS1-E

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sunny
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January 5, 2020 - 12:46 pm
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hi Joe     the  twin  swiiiitch    D7  has  a  batery         disconect  it ,,, and  then locate  &  clean  ALL   the   conncters   in  the  system  & reasemle the   ,,none   of the  3    D 7  lecy   sysems     let  the  headlamp   work  unless  the  motor  is  runing        ,,page  84   HAYNES  manual      if your  D7  has  BSA fited  wiering   &  charge   the  batery   

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NeilB
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January 5, 2020 - 2:47 pm
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If the horn is also not working, I'd suspect either the dip switch, or possibly not earthing properly either from the switch itself, or through the bars.

Bypass the switch, or check resistance between the bars and battery 

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Geoffrey25
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January 11, 2020 - 7:39 pm
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Hi all replaced dip and horn switch today and still no headlights and no horn I'm not really sure what I'm doing because a lot of the wires don't match colours of a normal d7twin switch diagram.The only colour that matches is pilot light and that does work ,the back light works with main headlights but no actual headlights for low or high beam ,the horn has always been connected with a brown wire joining a purple wire that used to work but not any more any ideas please many thanks Joe.

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stubaker58
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January 11, 2020 - 10:41 pm
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Hi Geoff,

whereabouts are you? It maybe someone can pop around and have a look. You could also post some pictures of the inside of the headlamp. I see you have checked the earths as that’s what the problem usually is.

As suggested above the best way forward is to disconnect everything and then go through one at a time reconnecting until you have light and sound.  If it was working and then stopped it may simply be a wire broken inside it’s insulation.

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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NeilB
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January 11, 2020 - 11:50 pm
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My first thought would be the headlight switch itself, I'm pretty sure that the internal connections for the headlight and tail light are separate, but I will check in the morning 🤔 

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carpetralph
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January 12, 2020 - 8:48 am
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The fact that the horn stopped working at the same time as the lights is a clue. As far as I am aware the horn takes its power direct from the battery, and is simply earthed through the button on the handlebars, and relies on a good earth through the bars, headstock bearings etc back to the battery. 

I would use a short length of wire and connect from the earth side of the horn to a good earthing point nearby (bolt head, engine casing etc). If the horn works it at least proves that a/ its not faulty and b/ the battery has plenty of charge in it. That being the case then the fault lies with the wire from the horn to the button, or the earth path from the bars.

The lights are a different matter, as they are no way connected in the switch with the horn, but do need a good earth and again that seems to be the main suspect. might be worth running a new earth wire from the headlamp shell straight back to the battery earth terminal to eliminate that as the possible cause and go from there.

Good luck.

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Geoffrey25
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January 12, 2020 - 2:18 pm
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Thanks for all your replies I have now got horn working and headlights are both working on low  and high beam it was to do with different colour wires on a new horn and dip switch.However having got headlights working has now knocked out the tail lights I'm not sure what's going on here ,can anyone tell me if positive earth which my bantam is does it mean that frame is live all the time.I Know that horn,pilot light and brake light run straight from battery but does it mean that the frame is  live even though I have earth lines connected?.

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NeilB
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January 12, 2020 - 3:43 pm
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Positive earth just means the frame is connected to the positive terminal of the battery, rather than the negative terminal like on modern vehicles. Technically from an electrical point of view, positive earth makes more sense as electricity flows from negative to positive. 

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mike p5xbx
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January 12, 2020 - 5:24 pm
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NeilB said
Technically from an electrical point of view, positive earth makes more sense as electricity flows from negative to positive.   

Does it ?
Would have been ok if you had said electron flow

“In the scientific and engineering world, and in all the literature and books, everyone "knew" that in a circuit, electricity flowed from the positive battery terminal to the negative terminal.”
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NeilB
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January 12, 2020 - 7:05 pm
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As that article says, electrons flow and everything else stays put, to suggest electricity flows the opposite way to the direction the electrons move is like suggesting a river flows the opposite way to the direction that the water moves. dunno

I feel like this is why "knew" is in quotation marks? 

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Geoffrey25
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January 12, 2020 - 9:18 pm
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Hi all so does this mean that my bike is correct to have electrical currant active on the frame  of a bantam many thanks Joe.

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Stoo63
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January 12, 2020 - 10:11 pm
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Yes, absolutely, Joe. Nothing to worry about there. Just how are we going to get some of that juice to your rear lights now? Process of elimination, I'd say, as the wire colours have been changed over the years and dont correspond to the wiring diagrams you have. You must be very close to success as the rears were working a couple if days ago. Something must have come loose, been disturbed when you were sorting your fronts. Two steps forward, one step back often but you'll get there soon and you're knowledge if your loom and bike's system will be so much more. All part of the fun! 🙂

All the best

Stewart

'52 D1 direct lighting plunger, '58 Square Four (project), '59 D1 direct lighting plunger,  '59 Tiger Cub, '60 5TA,  '76 FS1-E

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mike p5xbx
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January 13, 2020 - 12:27 am
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NeilB said
to suggest electricity flows the opposite way to the direction the electrons move is like suggesting a river flows the opposite way to the direction that the water moves.
  

the similarity to water flow is correct
Conventional current flow is from positive to negative, you can test that with an ammeter, battery and bulb experiment
but at the same time the actual flow of electrons is going in the opposite direction in the circuit.
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cocorico
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January 13, 2020 - 7:30 am
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Joe - if you start worrying about electron flow you will not make a lot of progress on your Bantam - the theory is not required for maintenance. All you need to remember is that you can have a +ve earth system OR a -ve one. The only items that can be affected are diodes and electrolytic capacitors. As your bike is the original 6V +ve earth system, you have nothing to worry about as you have no electrolytic capacitor and the rectifier is (presumably) connected appropriately. Don't get too deep into electronic theory, it isn't necessary for low voltage old motorcycle electrics (and I mean 'electrics', not 'electronics').

1956 D3 running, lights to sort. 7 other bikes in the Barn. 1950 D1 engine being rebuilt (slowly).

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sunny
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January 13, 2020 - 9:48 am
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its  not   goner  mack  any   difrants   to  how  you  referb     the  sytem      so   clean   the  wiering  and  parts   for  a  good  lecy   flow  wot ever  your going   for and  have   fun   

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Geoffrey25
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January 13, 2020 - 9:06 pm
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Thank you for all your replies I guess that a bit of checking on earth leads is needed I will  have a look at the weekend many thanks Joe.

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