Headlight, or, Why Do I Keep Tinkering?

[hop along]

Ok,
So As some of you know I have had a HID style light in the stock reflector for awhile.  After electrical issues last year in the charging system, the R/R was replaced as was the Stator, with a Mosfet R/R and Ricks Electric Stator.  I've also cleaned up a lot of other wiring on the bike for the accessories I have, including a fuse block.  And I went back to the stock H4 headlight bulb setup.

Everything was fine, then I decided I still think the stock headlight is terrible for light output, and found my way to a very positively recommended vendor called Eastern Beaver that makes all variety of wiring upgrades etc etc.
One such available upgrade is to add Headlight relays to help the bulb receive full power.  I didn't see anything in the wiring diagram to suggest there was some other existing relay so I bought and installed it.

This where I hate myself for continually tinkering.  I should just leave well enough alone.  But I don't....

So-the headlight now doesn't work, EXCEPT for the moment the key is switched off.  The long story is below (with the vendor's response)-and he asks if the Magna has a "Headlight Monitor Box"  What the heck is that?  And does the 3rd Gen Magnas have such a thing??
Hop Along, who was hoping to ride from OKC to KC this weekend...

>Finally getting around to an H4S-F relay install, on a 2003 Honda Magna cruiser.
>
>My purchase included posilocks option and bare wire ends for a fusepanel; the fuse panel I already had on the bike is a Centech AP-1 type. All circuits on the panel turn on when the bike is turned on, none are always live. It might be worth noting that all the other circuits on the fuse panel are functioning.  As part of my troubleshooting I tried using different circuits on the fuse panel, with no change in the situation.
>
>Anyways, all the kit connections are per instructions. During testing with no fuse installed, relays don't click. Testing with fuse installed, relays click, only with key on/off cycling; but headlight doesn't come on. There is no relay click when the hi/lo beam switch is toggled back and forth while key is on.
>However the interesting part is that the headlight *does* turn on briefly when the keyswitch is turned off-hi and lo will both do this! Headlight does not turn on when the keyswitch is turned on.
>
>I am not a master electrician, but this has my brain hurting-I don't see how the system could be only intermittenly functional.
>
>Are you able to make a suggestion as to what to look at next?

Scott, I'm not sure but check all the basics again, battery leads not reversed,
HI and LO hot wires connected to the PosiLocks. Even if you reverse those the
beams are reversed but everything still works.

It sounds like your bike might have some kind of headlight monitor that senses a
beam is out and it thinks that is the case since the headlight wires are no
longer supplying much current.

So what to do, well you can do some detective work and wire the HI LO connection
off the wires that enter the headlight monitor box, or you can give up and
return the kit for a refund.

I'm sorry I haven't heard of this problem for some time, only on the old
Kawasaki Voyager had this type of monitor and couldn't use a relay kit without
digging into rewiring as mentioned. Basically you had to cut the headlight
monitor out of the system. Warning, they can be more complex than you think.

The HI/LO wires that come off the handlebar HI/LO switch are the best place to
connect the posilocks too and that is what I suggest. Leave everything else
alone, just wire those wires directly to the Kit's Posilocks.

I mean, she's not a brand new bike and you want bright headlights so it's your
choice, dig in and fix it or go back to where you were and return the kit.

[hootmon]

I don't believe there is any headlight monitoring system on the Magna.. It is ALL basic stuff.. The CPU effect the timing and that's about it.. Everything else is basic relays, and switches.

[hop along]

Hoot, that is what I kind of thought too.  Apparently the vendor has seen this complication on Voyagers of years past. 

So this is the newest-I will reply with pics tonight hopefully.  And it looks like maybe I will be riding the DR this weekend hehe

Ken [who is Ken lol], these results sound strange, like some wiring might be out of place. Can
you send me a few pics showing the wires around the relays and H4 sockets
please.

>I did check voltages in various scenarios, do these seem correct?  Measurements are taken with digital multimeter, negative probe to bike frame ground.
>Key Off-no voltage present in circuits anywhere.
>
>Key on, Lo beam on, Posilocks Removed:
>Wire from handlebar, Lo beam-12.4v
>Wire from handlebar, Hi beam-0v
>Wire from Relay, Lo beam-12.5v
>Wire from Relay, Hi beam-12.5v
>Kit Socket: only black wire has voltage, 12.5v
>
>Key on, Hi beam on, Posilocks Removed:
>Wire from handlebar, Lo beam-0v
>Wire from handlebar, Hi beam-12.4v
>Wire from Relay, Lo beam-12.5v
>Wire from Relay, Hi beam-12.5v
>Kit Socket: only black wire has voltage, 12.5v
>
>Key on, Lo beam on, Kit wires hard wired to Switch Hot Leads, measured at the hard wire connection:
>Lo circuit, 12.5v
>Hi circuit, 12.3 v
>Kit Socket: only black wire has voltage, 12.5v
>
>Key on, Hi beam on, Kit wires hard wired to Switch Hot Leads, measured at hard wire connection:
>Lo circuit, 12.3v
>Hi circuit, 12.5v
>Kit socket: only black wire has voltage, 12.5v
>
>It almost seems to be that both the relays and switch hot leads are trying to provide power to each other... but shouldn't the relays be receiving power as their signal to then send power to the Kit socket?
>
>Ultimately I hope to confirm (and understand) that the system works correctly; I do have a second bike I was considering installing this kit on (a Suzuki DR650) but didn't want to commit to it until I had it functioning. 
>Thank you for your time,
>Scott Henkels

[Smoked U]

I think you need a girlfriend to keep you occupied so you don't think of these things so often

[hop along]

Well my recent hair donation (to Wigs for Kids) is getting me plenty of attention.  Too much in fact!!  Should've donated long ago apparently!