OK. So my brain fart stopped long enough to “stop guessing” about the color of the wire. Instead, I peeled back the rubber insulator and compared where the different colors are connected!!!
The OEM light (upper pic) is wired, Blue is ground, (on left) Light Blue (LB) is Low Beam (LB!), in the center position,and Yellow is High Beam, on the right side.
The “Other” Light (lower pic) when the wires are compared both by position and by testing with a direct connection to a fresh 12v battery, Green is in the ground (left) position, White is in the Low Beam (center) position & Blue is in the High Beam (right) position. So I am confident this is how they need to be connected, and is currently how the headlight is connected.
The issue STILL remains that it appears no power is being supplied to the headlight any longer. Visual inspection of both the wire schematic & the inside of the Hi/Low light switch indicates that power is supplied to the headlight by the green wire coming from the Voltage Regulator Green wire, Before the AC/DC switch.
This means the AC/DC switch does NOT control whether power gets to the headlight because the AC/DC switch is after the connection from the Voltage Regulator to the headlight switch.
So, either I am not getting power from the output side of the voltage regulator, or, the voltage regulator is somehow grounding out before the power makes it to the Hi/Low switch on the bars.
The Hi/Low switch is both complete and also has no shorts in it, as the solder joints are not broken and the ball, which makes the connectivity between two of three wires, which pair together by contact with the ball bearing in the switch, which can be adjusted between the Green/LT Blue or Green/Yellow, providing power to the headlight filliment of choice by the switch.
Tomorrow, (when I have available ambient light from outside) I will connect a spare wire from the battery to the green wire supplying power to the light. If the lamp lights up on one or both positions with the switch, this would be a good indicator that the connections at both the Hi/Low switch are working but not getting power.
Since the power passing through the green wire to the Hi/Low switch comes directly off the connection provided from the Voltage Regulator, I can then try switching out regulators and see if there is a failure of the Voltage Regulator.
Now, can anyone tell me IF there is a way to test the Voltage Regulator for output and/it connectivity? I am not 100% certain ifctge spare Voltage Regulator indeed works. However, if I swap them out and the headlight works again, I will at least know the current regulator quit working.
So that’s where I am.
Regarding meter testing, that was indeed strange. I was getting voltage readings of anywhere from .5v to 11+v from both the Hi and Low Beam wire connectors when paired with the common ground. Voltage fluctuated quite rapidly with throttle position, which could be another indicator that the voltage regulator is not functioning correctly.
More to come.........
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