ACE 100 Strange headlight rewire...Please help!

[COAce100]

So this is a two part question...

1. The workshop manual says that the headlight size is 5" 6v sealed beam. Haven't been able to find ANYTHING in that size. When I measure the the bulb, it seems like a 5 3/4 inch might fit(which happens to be all I can find). Anyone have any experience trying to use a 5 3/4" for an Ace 100? I have the original one that came with it, but the previous owner used some weird connections to jerry-rig it.

2. It seems that the previous owner did some rigging but the end result is only two terminals(instead of 3 prong), and I couldn't get the headlight to work. I've traced all the wire back and everything seems to test OK, but no power to the light. I've also confirmed that the headlight bulb does work(by connecting directly to batter). I've taken apart the headlamp switch on the handle bars and sanded/solvent the connections to make sure everything is working. I'm seeing some inconsistencies between the workshop manual and the rest of the wiring the headlight housing. It almost looks like there should be a ground wire going between the two speedometer indicator lights, connecting then to the ground of the headlight(light blue wire), then grounding all 3. The pictures below don't don't look too clear but this is what I'm seeing...

Brown wire ends on bottom of speedo light #1(light behind odometer)
Red goes to same spot of speedo light #2(high beam indicator)
Blue wire coming off of speedo light #2 connecting to ground of headlight socket

Everything else seems correct, but I can't even get the speedo lights working(and the bulbs are fresh).

Could it be lack of headlamp to complete the circuit? Grounding issues with speedo bulbs? This is kind of the last step for me to have this thing in good condition, so ANY guidance or suggestions are appreciated.

Thank you thank you thank you!

[COAce100]

Has anyone tried a 5 3/4" sealed beam application for the ACE 100 assembly? I've found a couple for pretty decent prices, that I'm sure would work(even found a 6v 15w/15w bulb for the socket. I'd be happy to share if someone can give me some insight on the above...

Bueller?

[Dale]

There are several posts on this site that cover issues with headlight wiring, lamp replacement and ignition wiring for Ace 100's. Do you have a toggle switch on the underside of the headlight bucket? This is known as the emergency switch. Also, do you have a 3 position key switch?

Try searching "Ace 100 headlight" and "Ace 100 ignition" in the search window and you should find some information.
Dale

[COAce100]

Thanks Dale. I have scoured the forums to find my answer and have found some insight, but not exactly what I"m looking for. It does not have a toggle switch on the bottom of the bucket and I do have a functioning 3 position switch.

[rlkarren]

COAce100... it sounds like you have an early Ace 100. You can use the wiring diagram for the Ace 90 to troubleshoot your problem. They are the same except the ignition coil. The Ace 90 used a single ignition coil, the Ace 100 used two. Except for that, they are the same.

On the Ace 90/Early Ace 100 machines, you only have brake light, (not tail light, only stop lamp with brake engaged), and horn with key in first position, whether the engine is running or not. With the key in 2nd position, engine off, you have the same.

The stop lamps and horn operate off DC current from the battery. Everything else, except headlight, operates off rectified AC current, regulated by the battery, directly from the magneto. The headlight is operated directly from the magneto and the voltage is not regulated.

Verify your DC circuit is working correctly, then we can tackle the AC side.

Roger

[rlkarren]

I've found a couple for pretty decent prices, that I'm sure would work(even found a 6v 15w/15w bulb for the socket. I'd be happy to share if someone can give me some insight on the above...

Bueller?

Tell me more about this. I've been working on this one for awhile.

[COAce100]

Dale, THAT must be what I'm not understanding. I didn't realize that some were powered AC and others DC. I have the tank off now as I'm having some corrosion fixed and have been working on the electrical with out the bike up and running. Duh. Thanks so much!

So here are my findings as far as lighting solutions:

I've read that 5 3/4" sealed beam will fit early ACE housing. Assuming this is true, I've found the following. I'm going to order a couple different ones to find out which works best...(after I get the tank bank on)

GE 4020. There are several different manufactures that use this same number as spec but they all seem to be 6v 30/30. Same connection terminal and size.

$19.50
http://www.normanlamps.com/product_info ... ts_id/3839

$29.99 This one is a 6v 25/25
http://www.wpsracing.com/bu536sebe.html

This is the closest I think, and would only require that you remove the 3 prong tether from the original harness and the chrome housing that's included. If you scroll down on that page, you can see 6v 15/15 which would need to be purchased separately, but is the same socket size/type.
http://dratv.stores.yahoo.net/ecveofaoffro.html

All of these seem cheaper than what I've been searching as "Hodaka replacement sealed beam" hah

Thank again Dale. Appreciate the insight.
-Brent

[Dale]

Brent,
I think you mean thanks for Roger. He is on top of the Ace 90/100 wiring...
As for the AC vs DC, some models have the emergency toggle switch. Typically you would have the switch in the AC position. In an emergency you can switch to DC. This was to save the battery.
Dale

[rlkarren]

That Beatrice Cycle light is a 4 1/2 inch housing and would be too small for the Ace headlight bucket. I saw that one too and got excited until I realized that it was a smaller light.

The others look interesting... Although you'll want to get as close to 15/15w as possible. The reason for this is that the Ace 90/100 light coil only puts out about 18-20W. If you run a 25W bulb, you'll drain the battery rather than charge it every time you brake, theoretically. In most cases this would be OK, but you also run the risk that the bulb will not even power on since it requires 25 watts. If you have a 6v 15/15w bulb, protect it with a voltage regulator. I've been looking at this item: http://www.regulatorrectifier.com/catal ... -Rectifier

One other thought is a 12v 55/60w bulb. If I calculate correctly it will burn at 6v 13.75/15w, but it will look like it's underpowered.

I've thought of many ideas but nothing really solid yet for the Ace's. What it comes down to is the best option is to find a source for a 6v 15/15w H4 halogen bulb. Then those Autopal or Candlepower reflector/lenses will solve the problem for everyone.

Roger