X10 Headlamp fault

[roadster]

Just a year old and my X10 has its first fault. The headlamps ( main and dip ) stopped working even though I could still flash main beam from the switch. After checking the fuses I turned to the workshop manual but unfortunately the electronic copy does not have any readable wiring diagrams. There was a mention of a headlamp relay but no clue to where it was located.

So I stripped out the handlebar switch and decided after much head scratching that there was no live feed to the dip-switch. I then took off the screen and the cover beneath it to see if I could find the relay or trace the wires. Not much luck there although I did confirm that the connections from the handlebar switches go direct to the headlights and no relays are present in that circuit.

This is where the circuit design is very odd. The conventional use of relays in high current circuits is to provide a short and direct route so the relays are normally controlled by the dip switch and flasher switch which can then be low current switches. But in this case not so. Going back to the workshop manual it refers to some relays which are on the fuse box backplane. There are three of these but there is no description of their function or which is which. Eventually I found that the front left relay is actually for the headlamp supply and this seems to have an intermittent fault. I've given it a thorough clean up ( although there was no sign of corrosion or overheated contacts ) and it is working at the moment.

Of course this is in the area of the notorious exposed fuse box connection block but I have had this protected almost from day one so if there is a fault it is not caused by corrosion as such. If all three relays are identical I might try swapping them around but as at least one of them prevents the engine running when removed this might not be the best idea.

If anyone can come up with a readable wiring diagram for this model it would be hugely appreciated.

[frankiej1949]

What about the warranty?

[Dave Milnes]

On the old bikes which had a light switch power was taken from a fuse to the switch and first position went directly to the sidelights. Second switch position went to actuate a relay that took power from a second fuse and fed the dip switch which toggled low and high beam. A second live fed via another fuse also fed the dip switch for flash function but not through a relay so you could do this with the lights normally switched off. I suppose they thought the momentary use of the flash didn't warrant a relay.

Once always on lighting was introduced basically all Piaggio seemed to do on the X9 models was take away the light switch so feeding the sidelights directly from their fuse and making the switching feed to the headlight relay also directly fed from it's ignition live fuse.
Now on later models I would have thought they gave this more thought, and correctly used a relay for each beam as they did in the Honda powered X9 250SL, but I guess as there is in standard form only one 55W light on for each beam a single relay would suffice and the dip switch would cope with a mere 4.5A passing through it. If however you have linked the dip and main wiring so the dip remains on at high beam, the dip switch is now passing 9A which is enough to 'warm it' slightly and also the relay is being asked to pass twice the current, it could be the relay isn't man enough for the job and a cheap low cost Chinese piece of s**t. Replace with a meaty 15A Bosch item and it will probably last the bike out.

[roadster]

What about the warranty?

First consideration is that I have no dealers nearby. Second is that I have no confidence that they would have found this fault any quicker than I did. If it turns out that new parts are needed (and so far its been OK since I 'fixed' it) then I would contact the dealers now that I can point them at the cause immediately.
I bought the scooter with eyes wide open knowing that dealer coverage in this area was poor and to be frank that is why I went for the cheapest on-line deal.

By the way I haven't modified the headlamp so that both beams are used on main beam. If I did I would take on Dave's point and add an extra relay rather than just using the headlamp flash live feed which as I now know bypasses both the correct fuse and the relay.

Incidentally the relays used have some internal electronics so if I was looking for a replacement I would have to see whether that is anything more than surge or back current protection. The role of this relay may be to prevent the headlamps coming on before the engine is running so it could need some more thought.

[Dave Milnes]

The circuit must be the delay timer. Similar relays must be used on other bikes from Japanese makers so could be of better quality.

[Globs]

It sounds like it would be easiest to just order a new relay from Piaggio....

[roadster]

Its been working OK since I cleaned it up and I must have done about 80 miles with plenty of rough roads. Fingers crossed I won't need a new one.

Well that was wishful thinking! It lasted about a week then failed again. I have just fitted a new relay from Fowlers ( very quick delivery). All three relays are identical, here are the details:-

Microrelay 12v 30A

Part no 643452

It can be very difficult to find from the parts drawings but just search for the number or description.

[Mike H]

Just FYI this is the same ~ as said this style is called 'micro relay'

http://www.rapidonline.com/Electronic-Components/12vdc-Spco-Automotive-Relay-Srz-60-1910


As far as I can gather from how it works, the headlight relay is not on a delay, it holds off headlights being on until engine is running. But if you stop the engine with kill switch ot sidestand headlights do not go off again niether does there seem to be a time-out to turn them off.



Also FYI I discovered that the 'lone' relay 'by itself' i.e. next to the blank empty relay position, is the fan relay, AND it's switch contacts are permanently live. That is, battery positive.

This alone attracts oxidation and corrosion, and so will be aggravated more than somewhat by the spray thrown up into the fuse box from the rear tyre issue!

You can test the fan by bridging terminals 30 and 87 of the base socket and fan should run.

HTH