1980 Z1R Low beam, high beam indicator, head lamp warning, hazard issues

wrote:

I just scanned the FSM wiring diagram.  I should show up as an attachment to this post. 
I saved it as a PDF so that this site would not reduce the image size (as it does with JPG files).  It was scanned at 600 dpi so all the detail should be there.

Thank you, now I know why photos I post are sharp in my tablet but fuzzy when posted… 

For the hazard, it doesn't look like the hazard system and the headlight system have any link between them.  Other than both have signals that go through the left handlebar switch. 
I would check to hazard flasher again.  If you disconnect the hazard flasher, you should see 12V (measuring wire to ground) on one of the two wires when the ignition is on.  If you short across the hazard flasher, that is directly connect the two wires for the flasher together, all four turn signal lights should come on when you activate the hazard switch on the left control block.  

For the headlight, you mention that the headlight failure light is on, but the headlight is not on?  If the switch is in the low beam position and the headlight failure light is on, you should see the high beam filament on instead.
The intent is that if the low beam filament fails (open circuit), the Reserve Lighting Device is supposed to detect the fault and switch on the high beam filament instead, but dimmed somewhat by passing it through the resistor block under the tank.
The same thing happens for the tail light.  If the rear running light filament fails, the Reserve Lighting Device switches over to the brake light filament.  But the brake filament is dimmed by the other resistor in the resistor block, so when you actually engage the brakes the light still gets brighter like it's supposed to.

I would start by checking the connections and cleaning the contacts for the Reserve Lighting Device and the resistor block.  I had to zip tie the connectors together for the Reserve Lighting Device on my bike as they wanted to slide undone very easily.

You could also look at the contacts for the left hand switch block.  These are on the left side of the frame under the tank.

 

Am I right in thinking the turn signal control unit operates the front turn signals as “marker lights” I noticed there are three wires on the front turn signals ?

Mikaw post=863731
Thank you, now I know why photos I post are sharp in my tablet but fuzzy when posted… 

I think I learned about this when trying to post a wiring diagram in the past.  All of the image files uploaded to KZRider as attachments are automatically downsized.  Looking back through my posts, it seems the magic number is a maximum of 1200 pixels for vertical resolution.

Most of the time you don't notice, but things like wiring diagrams really need to be hi-res.

 

wrote:

Am I right in thinking the turn signal control unit operates the front turn signals as “marker lights” I noticed there are three wires on the front turn signals ?

I see what you're looking at....  The front turn signals have three wires, and use a 2-filament bulb.  The "marker light" wire is the blue wire, and these may be powered directly from the ignition switch, along with the gauge illumination.

I think it goes like this.  Battery to 20A fuse to white wire to ignition switch.  Ignition switch white wire to brown wire in "on" position.  Brown wire to 10A fuse to blue/red wire.  Blue/red wire to gauge illumination and front marker lights, and also blue/red wire to ignition switch.  Ignition switch blue/red to red that feeds into Reserve Lighting Device.

If that's right, the marker lights are powered directly from the ignition switch, but maybe the Reserve Lighting Device is powered from this same 10A fuse?

I think there is a missing junction dot on the brown wire that comes out of the ignition switch.  Maybe it's supposed to be here?

 

wrote:

For the hazard, it doesn't look like the hazard system and the headlight system have any link between them.  Other than both have signals that go through the left handlebar switch. 
I would check to hazard flasher again.  If you disconnect the hazard flasher, you should see 12V (measuring wire to ground) on one of the two wires when the ignition is on.  If you short across the hazard flasher, that is directly connect the two wires for the flasher together, all four turn signal lights should come on when you activate the hazard switch on the left control block.  

For the headlight, you mention that the headlight failure light is on, but the headlight is not on?  If the switch is in the low beam position and the headlight failure light is on, you should see the high beam filament on instead.
The intent is that if the low beam filament fails (open circuit), the Reserve Lighting Device is supposed to detect the fault and switch on the high beam filament instead, but dimmed somewhat by passing it through the resistor block under the tank.
The same thing happens for the tail light.  If the rear running light filament fails, the Reserve Lighting Device switches over to the brake light filament.  But the brake filament is dimmed by the other resistor in the resistor block, so when you actually engage the brakes the light still gets brighter like it's supposed to.

I would start by checking the connections and cleaning the contacts for the Reserve Lighting Device and the resistor block.  I had to zip tie the connectors together for the Reserve Lighting Device on my bike as they wanted to slide undone very easily.

You could also look at the contacts for the left hand switch block.  These are on the left side of the frame under the tank.


DOHC,
I will measure the voltage at the flasher to see if thats what has failed. In regards to the headlight, the headlight out light is on, and the low beam is not, but you have to flip the switch to high beam to get it to come on. The high beam is not coming on automatically. That makes me think there's an issue with the RLD. Where is that located on the bike? I've never seen it before. I will check all the connections for the Resistor and the RLD and go from there. Thank you for the very insightful post. 


 

wrote:

Where is that located on the bike? I've never seen it before.
 

Here is an example of what it looks like:

ebay.com/itm/294805722951

I don't know where it is on the '80 Z1R.  On the '78 Z1R it's behind the right side cover, but there is a photo of this area for the '80 model in the manual and it's not there.  Maybe it's under the left side cover?  I know the harnesses are very different between the '78 and '80, and they removed a connector block under the left side cover for the '80.  Maybe they put the RLD where that was?  I can't find a picture in the manual.

 

That looks like a very reasonable price for such a rare part, I’d be inclined to buy it regardless as a spare (I would think you could always sell it on)

wrote:

wrote:

Where is that located on the bike? I've never seen it before.


 

Here is an example of what it looks like:

ebay.com/itm/294805722951

I don't know where it is on the '80 Z1R.  On the '78 Z1R it's behind the right side cover, but there is a photo of this area for the '80 model in the manual and it's not there.  Maybe it's under the left side cover?  I know the harnesses are very different between the '78 and '80, and they removed a connector block under the left side cover for the '80.  Maybe they put the RLD where that was?  I can't find a picture in the manual.

It is behind the right side cover. I cleaned the connections to the RLD and no change. I tested the connections for the hazard flasher, no power with ignition and hazard switch on. I’m going to inspect the switch connector next. Where is that resistor block located?



 

wrote:

Where is that resistor block located?

On the '78 the resistor block is mounted below the ignition coils, hanging down above the valve cover.  

Edit: Another eBay link for pictures:
ebay.com/itm/353894409134

Fixed the hazard problem by cleaning some connections from the handle switch to the main harness. Still dealing with the low beam issues, looking for that resistor now.