Edit: Problem Solved. Turned out to be the green and brown power wire as suggested. The pin in the main headlight connector was corroided and slightly burnt. I had to pull it out and polish it up and use some di-electric grease on the connector. This is on a completely stock bike, so it seems that possibly riding with your bright on all the time is just putting too much stress on this one wire that powers the headlights, turnsignals, and tip over sensor!



Well, I've officially had my first issue with my 02 F4i. Went to turn it on and noticed that the highbeam, and both signal lights on the gauge cluster stay lit all the time. The headlight is super dim, and the flashers stay lit all the time. The bike will start up like normal, but if i hit the turn signal it will immediately die. If i pull the headlight fuse the bike will start like normal, and the gauge cluster will not light up both signals, but of course I have no headlight? Anyone know what could be going on?

Also just noticed that the fuel pump only primes with the key in Accessory with the Headlight fuse pulled. When the headlight fuse is pulled the 3 unwanted lights on the gauge cluster go away too. All fuses in the small fuse box under the seat are fine. Are there fuses anywhere else I should check?

 

check the headlight connector, green ground wire

 

Dunno, shorted or loose connector somewhere, maybe worn wiring somewhere. If you have a friend with an F4i, you could try his ECU on your bike to make sure thats not the problem.

 

is the green headlight connector located right behind the bulbs?

 

its a gray connector and i believe its around the left headlight when sitting on the bike. I know thats been an issue of some sort with the turn signals lighting up on the dash. Provided you havent added any mods this is more then likely the problem. Check to see its not pull out and put some dielectric grease on it. I had it all apart and greased everything up during winter

 

thanks, any other suggestions?

 

well it definately seems there is a problem somewhere on the headlight/front blinker wiring. Anyone got any ideas or tips to check?

 

get hold of a multimeter and check for shorts using the resistance setting and the wiring diagram from the service manual... that's the long way to do it. if the bike dies then its probably a short.

 

I had this same problem on my f4i last summer. It baffled me for a while until I broke out my multimeter and found that it was a bad ground from the headlight, high beam if I remember correctly. Take the negative wire, splice in another wire, preferebly black (for negative) and run a wire to another ground already on the bike. For example I tapped into the ground of the headlight and ran the wire to the ground to the top left side of the radiator where there is a bolt that connected to the frame. You can see this bolt on through the left fairing. This location has other wires running to it, for a ground. Wrap the wire in wire loom, or something to protect it from the heat. Since that, I haven't had the electrical problem again. Hope that helps.

 

glad ya got it fixed. I too had the same problem with the connector w/ the exact same problems. Did the same fix as you and been over a year w/ no issues. There are quite a few that have had that odd problem as well.