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Troubleshooting an electrical problem on Baja Designs Kit.

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Hi all,

I have an older Baja Designs dualsport kit on on my '99 XR400. I cannot seem to get the headlight to work. There is not any voltage going to the headlight. I have voltage coming from my stator. The battery charges. My turn signals work. I have checked connections. I dont have a wiring diagram for this application so if anyone has one.... The headlight did work and I also noticed that the power light on the Baja Designs kill switch is not working. Any Ideas on things to try?

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Have you done the obvious and checked BOTH filaments of the bulb?

In line fuses?

Connections must be corrosion free. Good grounds.

Any inline relays?

There are a few different wiring diagrams floating around. This one: for more recent kits for bikes with kickstarters.

www.bajadesigns.com/.../Wiring%20Diagrams/Dual%20Sport%20Kit%20Schematic%20-%20New%20(kickstarts)

and these:

http://www.4strokes.com/tech/images/baja_designs_schematic.gif

http://www.4strokes.com/tech/images/baja_designs_wiring.gif

If all else fails, call BD tech support.

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The bulb is good. The switch doesn't seem to have power. I guess it's gonna be the tedious way. One section at a time until I find the problem. Thanks for the replies.

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I was looking on there but didnt see one. I might just give them a call..

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Thanks 3. I didnt see that on there. But its nice today so its time throw it back together and go riding!!

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Fixed!!! :thumbsup: It turns out the FET was bad. The newer kits dont have one. The solution was to just remove it . Thanks 3inthedirt for pointing me to the troubleshooting guide.

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Glad you got it fixed, mine needs a battery as the lights are virtually non-existent at idle....

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