Stelvio Light Issue

[smdl]

Hi, folks.

I had a strange thing happen on my Stelvio when I went out for a ride, last night.  Just as I got into a really dark area, I switched to high-beam, and all went black (really exciting!).  I brought the speed down, got turned around without getting killed, and started back home.  By the time I got there, the lights had come back on.  I tested this again a few times (in the safety of my garage), and found exactly the same symptoms each time.  I haven't dug into it yet, but there didn't seem to be any effect from wiggling wires, etc.  Any thoughts as to what might be the cause?  It's obviously not a blown fuse (yes, aux lights are fused and they weren't turned on), as the lights recover after about 30 seconds of going out and switching back to low-beam.  Perhaps the switch is heating up and then cooling down again when the lights go out?  Would appreciate any input on the best place to start.

Edit:   I did replace the headlight relay earlier this year as the one that was in there was no good.  Interesting that this relay also impacts charging as whenever the headlight went out, the charging system died too.  Maybe this relay is failing?

Cheers,
Shaun

[Kiwi_Roy]

You don't have breakers instead of fuses do you?
Do the tail lights or any other lights stay on?

[smdl]

You don't have breakers instead of fuses do you?
Do the tail lights or any other lights stay on?

Nope, standard fuses.  I'm not sure about the taillight, but the dash stays lit, and I'm pretty certain that the small parking lights in the headlights stay on.

Thanks,
Shaun

[Markcarovilli]

Check Relay #65 (second back from the front of bike) this is the high beam relay....

Mark

[leafman60]

Ditto

check that relay

[smdl]

Thanks, will check the relay.  Although, if high and low beam user separate relays, shouldn't the  low beam come back on right away when I switch back?  This doesn't happen, at least not for some time after switching to low beam.

Right now, time to go for a ride. . Probably the last of the year...

Cheers,
Shaun

[smdl]

Well, unfortunately, I was not able to reproduce the problem today.  Will keep monitoring.

Thanks for the input -- will revive the thread if it happens again.

Cheers,
Shaun

[Kiwi_Roy]

Based on this schematic there are no relays for H & L beam, the headlight logic relay is just to keep the lights off until the engine is running.
With all those lights going through the dimmer switch I think that's where I would look first.

http://www.thisoldtractor.com/guzzi007/schematics/2008_Stelvio.gif

[Wayne Orwig]

The low bean is wired directly to the logic relay. The low beam does not go off, when you switch on the high beam. Yes it normally does run the low and high filaments at the same time.
So if all of the lights went out, it would not be in the high beam switch.

[canuck1969]

The low bean is wired directly to the logic relay. The low beam does not go off, when you switch on the high beam. Yes it normally does run the low and high filaments at the same time.
So if all of the lights went out, it would not be in the high beam switch.

Not on the newer version of the Stelvio.  When the HB is on, the LB turns off.  Both bulbs are LB/HB.

The HB relay is wrong in the schematic.  It is actually a 5 pin relay.  The normally closed terminal (87A) fires the LB when it is supplied power from the Lighting relay when the engine starts.  When you flip the HB swithch, the HB relay triggers and the normally open terminal gets energized (87) and 87A drops out and turns the LB off.  If you look at the Norge schematic, it is correct on that one.  Guess this Stelvio drawing still had the earlier version logic on it.

If both the LB and HB go out I don't believe it is the HB relay unless the wire that supplies its power from the Lighting relay is loose.   If the HB relay fails, it will fail open or fail closed, either way you will have lights (HB or LB).  Same goes for if the HB switch fails.  Either failure state will still give lights.

I would confirm that you have power to the center terminal (87A) on the HB relay when the bike is running.  If you don't , then the lighting relay may not be firing and you are also not charging. Start there with a new relay again and try to get the stock one or a Bosch equivalent.  You need a good quality one rated for continuous duty.

 I just had the same issue on mine.  Cleaned the relay with some contact cleaner and I didn't have lights or charging anymore.  Thought I blew the 30 amp fuse but no go.  Turned out that the contact on the inside of the relay got contaminated from the cleaning when it dried and stopped the relay from firing.  Some emery paper cleaned up the contact and all was good.

[smdl]

Thanks for the feedback.  Funny, I was just reading a thread where you were having this same discussion.  FWIW, I think Canuck is right for the later bikes.  When I look closely at the headlight bulbs, I can clearly see the two separate filaments as they light up (fore and aft), and they are not both on at the same time.

Will take a close look at the HB relay, but keep in mind that the lights would stay out completely for about 30-60 seconds after returning the switch to the LB position again. 

Thanks,
Shaun

[canuck1969]

Thanks for the feedback.  Funny, I was just reading a thread where you were having this same discussion.  FWIW, I think Canuck is right for the later bikes.  When I look closely at the headlight bulbs, I can clearly see the two separate filaments as they light up (fore and aft), and they are not both on at the same time.

Will take a close look at the HB relay, but keep in mind that the lights would stay out completely for about 30-60 seconds after returning the switch to the LB position again. 

Thanks,
Shaun

It Is possible that you have a corroded contact on the HB relay. It triggered and droped the 87a terminal but does not make full contact with the 87 terminal and then as the resistance builds it finally contacts.

I would take the relay apart and give it a good cleaning and bench test it. Like i said it only took a little bit of dried carbon on mine from the cleaning to stop the transfer. A bike t of emery beteen the contacts may be all it needs…or a new relay but I like the more entertaining method sometimes.