Motorcycle High beam stuck on - dual 5pin micro relays

[Meeky1nz]

Hi all,

Im new here and I am in no way electrically minded or trained but i am trying to learn. I have a Harley and I have equipped an Aftermarket headlight. I have put together a wire harness for it but it isn't working correctly and I can not figure out why. Ive been trouble shooting it for a week now which hasnt been the worst thing in the world as I feel as though I've learned some new things which is why i like to do the work on my bike myself but i am completely stumped now and need some assistance.
Please excuse my poorly drawn diagram below:
This is what I currently have. My high beam is stuck on which im thinking is because of the orange connecting wire between the 86 terminals: even when in low beam, 86 on relay2 will also be receiving power which activates the switch causing the high beam to turn on. But when I remove that connecting wire, I have Low beams when switch is in Low beam but when i switch to high beam all im getting is the back light. I checked the 86 terminal on relay2 and it is receiving power and i can hear the relay click but 87 isnt getting any power. I am assuming that if it was a wiring issue then the high beam wouldn't work at all?
I tried moving the blue low beam wire to 87a on relay 1 which worked but the light stayed on even after i had switched off my bike .

 

[Les Jones]

I think I can explain why the ready made harness works. In the diagram in post #1 I think the wire that links pin 86 on both relays in the ready made harness has a diode hidden in it with it's anode to the relay 2 and and it's cathode to relay 1. I suggest that you meter between 86 on the relays to see if is just a wire or there is a diode hiden in the harness. If it is made that way it will work with either of the two possible switch configurations. This saves having to make two versions of the harness.
This schematic is how I think the harness is wired

I think it is possible that there is also a diode in the orange wire between the switch and the junction of the diode on the diagrem and pin 86 on relay 1. This would prevent feeding 12 volts back into the switch when the green wire output was +12 volts.

Les.