Mk3 Headlight / Pilot Handlebar Switch

Today, I lubed my throttle cable. I opened the RH switch unit, to get to the top of the cable. Once it was back together, I can no longer get my headlight to work. Pilot light is on, and stays on when I move the switch to headlight. No mainbeam (on the LH bar switch) either.

There are 2xwires to the head/pilot switch. Both look OK. The spring and small ball are in place on the plastic slider. The small metal part within the slider that contacts the terminals seems tight and is moving with the switch movement. There are two wires into the switch and 3 terminals, but no sign of a stray wire? The starter button is working. I had a spare headlight bulb, so tried that, but still no light. Out of ideas. Any suggestions?

Mart UK said:

There are two wires into the switch and 3 terminals, but no sign of a stray wire?

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Should be a blue 'U' and a blue/yellow 'UY'.

There's no third wire to that switch so at the HEAD position there should be 12V at the U and UY plug connections.

I have >12v at the kill switch, nothing at the tips of the blue nor blue/yellow wires.

Mart UK said:

nothing at the tips of the blue nor blue/yellow wires.

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Power to the Head/Pilot switch comes from UY on Ignition switch T4 so it would seem there's no power reaching the switch from Ign.Sw. T4.

Oh dear. That explains it! I had moved the bars towards me a couple of days ago. Maybe a stretch too far. Otherwise, I've not been near them.

Can I put a fresh wire in, joining up to the existing cable, within the headlamp bowl? What fix would you suggest?

I've just looked in the headlight bowl, there are bullet connectors in there to the main wire that goes to the loom. It is also coiled up, there may well be enough currently in the bowl to reach.
EDIT: no, not enough.

Mart UK said:

I've just looked in the headlight bowl, there are bullet connectors in there to the main wire that goes to the loom. It is also coiled up, there may well be enough currently in the bowl to reach.

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Probably is enough as there was only one length of switch cluster harness wiring for both LH and RH clusters to suit all handlebar types including Hi-Rider.

Mart UK said:

EDIT: no, not enough.

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Unlucky.
Not quite the same as the moulded cable but as near as I think you will get.

8mm sleeve? The bullets inside the bowl are solder type. Are they reusable? 4.7mm?

Mart UK said:

8mm sleeve?

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I'd have thought 6mm would be closer to the size as there are only two wires in that section.

Mart UK said:

The bullets inside the bowl are solder type. Are they reusable? 4.7mm?

Click to expand...

Yes.
(It would have had a two-pin plug originally)

Thanks. Brilliant again.