Headlight only works on high-beam (77 KZ1000)

I was having problems with my LH control pod after I replaced my handlebars.

Everytime I would flip from High to Low beams a fuse would pop.

In addition, the low beam would and/still does not stay on after startup & revving up the motor. But, the High Beam stays on and does not dim when revving the bike.

I replaced the LH control pod and it fixed the fuse issue, as I assume it was a pinched wire.

I cleaned all the connectors throughout the electrical system and made sure all the wires matchup. I had new plugs, points, condensor, etc. also replaced. The battery is fully charged.

I took the RH control pod off and inspected it, but did not see any damage to the wires.

Any ideas? Rectifier/Alternator/Stator?

Low beam works when cold but not after warm up?

This:

Everytime I would flip from High to Low beams a fuse would pop.

makes me ask a dumb question: is it possible the low beam lamp is just bad?

I took it out for a test ride.

Low beam seemed to work the entire time I was riding, until I slowed down and parked it. Then it would go out. I would give it some gas and it would come back on.

This seems to be the pattern.

The High Beam works all the time.

No probs.

My old man said, "Screw it ride it with the high beams on and forget it."

Doesn't sound like a bad idea, except its pissing me off to no end trying to track down the problem.

I have not tried to put in a new lamp to see if that was the problem. I know the dillweed that sold it to me said it was new. Of course he said it was an 8 out of a 10 on craigslist. Well......with about and extra 1500 maybe a 7 now.

bountyhunter wrote:

Low beam works when cold but not after warm up?

This:

Everytime I would flip from High to Low beams a fuse would pop.

makes me ask a dumb question: is it possible the low beam lamp is just bad?

I have seen the headlight bulb elements barely touch and the light will work intermetly has the spring will vibirate. It will blow fuses doing this also . So get a good one to check that out first..

Remove the two screws holding the headlight to the housing,put a folded towel in case the headlight drops to the front fender, and disconnect the three prong electrical connector.

The headlight bulb should have a rubber dust cover that probably needs to push and twist to remove,carefuly pull the bulb out of the headlight lens and look for broken filament(s).

Thanks, I will try those ideas out tomorrow.

I'm a moron though, it does have a sealed lamp.

Damn, rain.

Thanks for the help. Fixed.

A simple idea of changing the headlamp fixed the problem.

This is after taking each wiring harness out as well as the control pods and cleaning them out. That took a while.

Now after getting the bike back to together and 10 minutes on the road, another recurring problem has mysteriously popped up.

Well its off to the brakes forum.