Alright so I have been working on the electrical system while im building the motor. So to start off with, Long story short the headlights will not turn on. I have power to the side marker lamp, interior lamps and even tail lamps. So here is what I have discovered, When I pull the head lamp switch 1 click, then all the marker lamps and such come on. While I have it in this position, when I put the test lamp on the positive terminal and probe the head lamp wire, the test lamp lights up. So correct me if im wrong but does this mean there could be something grounding out the head lamp circuit? Alright and second, If I pull the headlamp switch out on the 2 click then everything goes out, no power anywhere, but If I unplug the High Beam floor switch power is restored but still no head lamps. With the high beam switch unplugged I tried to manually jump the wires but I lose all power again. On the high beam switch I get have power to the center wire. Help or thoughts?
When you are probing the headlight connector, are you doing it while plugged in to the headlight? If so the light should light. How old is the switch, is it original? Some switches have a built in circuit breaker and it's possible that has gotten weak and can't hold the current. My suggestion is to get a multi meter, cheap at Harbor Freight if you have one, unplug everything and check the wires for continuity to the ground. Put the meter on the ohm setting, put one probe to the terminal and the other to the negative or a good clean chassis ground. All the powered circuits should read open and the grounds should show little to no resistance.
The yellow/red wire is the feed from HL switch, dimmer just routes power to low or high beam. As mentioned there are circuit breakers(two in fact) in headlight switch, with park being separate from headlights. I'd remove headlamps and check park lamp operation. If parks still have a issue, likely there is a wiring problem in feed to headlights. If parks operate in BOTH Hi & Lo positions without headlamps, likely main switch has problem(weak circuit breaker).
Ill look into a few of theses, I did get a new Headlamp switch its self and it replicates the exact issue. That is why it was leading me to another issue some where. Rain has delayed me today tho.
Update: Unplugged headlamp, tested switch and the high/low floor switch, with out headlamps plugged in, everything works great with the test light, I plug in head lamp, it dies out. Maybe I just have some bad lamp?
