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post #1 of 10 (permalink) Old 1-19-2020, 12:06 PM Thread Starter
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No headlight?

Gday all. I've got a 08 motor and wiring loom in a 85 454 frame. Now I'm about as good an electrician as plugging an extension cord into a socket. So I made a new loom. (How hard can it be) Well after a LONG WHILE of tooling around I purchased a second hand loom. Yay it works now. Then I modified the loom I made and I have all electrics working. Except for the headlight.
When I plugged in the new (second hand) loom into the bike the headlight worked for a moment. I turned the key off to not drain the battery.
But now it wont turn on again?
No fuses are blown, the headlight works when connected to a battery.
But I'm completely stumped as to why it wont turn on.
The Junction Box has a white and green sticker with the numbers 26021-1089.
Will the headlight only work when the motor's running?
If not could it be a bad Junction Box?
I'm really stumped.
Thanks guys!
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post #2 of 10 (permalink) Old 1-19-2020, 9:09 PM
bpe
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On the stock EX, the headlight does only work when the bike is running.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2020; 108,827 . It's a GO bike, not a SHOW bike.
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post #3 of 10 (permalink) Old 1-19-2020, 10:12 PM
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wowwwww hang on a bit I read you post twice just to make sure. you are putting a 08 gen 2 EX engine into a 84 454 gen 1 frame there are some issues you may not be aware of before you go any further. are you using the gen 2 wiring loom or gen 1 455 loom. it's important. if you use the gen 2 loom you also need ign switch off a gen 2 and the CDI unit. plus the connections for things like hand controls are wired differently.

if you are using the 454 loom you can keep the CDI and ign switch off the bike also the hand controls BUT the fly wheel is different you will have to modify the triggers on the outer rim to work with the hall sensor of the gen 1. check this before doing anything else.
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post #4 of 10 (permalink) Old 1-20-2020, 1:05 AM Thread Starter
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It's an 08 motor and full harness, I even got the gauges so the milage is correct to the motor.
I haven't fired the motor up yet as the carbs are still off the bike and the gas tank I'm making still has two side panels to build. I have a bottle for a gas tank that I made to fire it up in the shed. So that's for tomorrow night.
When i turned on the electrics (for 3 seconds) the head light turned on then got a bit dimmer. I'm not sure if the bulb stopped before I switched the ignition off or not?
So the headlight will only be on when the motor's running.
So it'll only be on once the motors started?
Not while cranking over?
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post #5 of 10 (permalink) Old 1-20-2020, 8:00 AM
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Be Advised

I will only be stating how the EX 500 works. Anything to do with mix-matching will have to be addressed by @yorkie , or someone else.
Quote:
Originally Posted by Gonzo454/500 View Post
So the headlight will only be on when the motor's running.
So it'll only be on once the motors started?
Not while cranking over?
^ This is correct.
Quote:
When i turned on the electrics (for 3 seconds) the head light turned on then got a bit dimmer.
^This is not correct. Whether it gets dimmer or not, the headlight is not supposed to come on.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2020; 108,827 . It's a GO bike, not a SHOW bike.
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post #6 of 10 (permalink) Old 1-21-2020, 3:52 PM
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Unrelated, but the 454 is belt drive, is it not? Are you converting the rear hub to a chain sprocket?
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post #7 of 10 (permalink) Old 1-21-2020, 4:46 PM
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Quote:
Originally Posted by Brimstone View Post
Unrelated, but the 454 is belt drive, is it not? Are you converting the rear hub to a chain sprocket?
doesn't need to just use the 454 front drive for the belt
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post #8 of 10 (permalink) Old 1-21-2020, 4:50 PM
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Quote:
Originally Posted by Gonzo454/500 View Post
It's an 08 motor and full harness, I even got the gauges so the milage is correct to the motor.
I haven't fired the motor up yet as the carbs are still off the bike and the gas tank I'm making still has two side panels to build. I have a bottle for a gas tank that I made to fire it up in the shed. So that's for tomorrow night.
When i turned on the electrics (for 3 seconds) the head light turned on then got a bit dimmer. I'm not sure if the bulb stopped before I switched the ignition off or not?
So the headlight will only be on when the motor's running.
So it'll only be on once the motors started?
Not while cranking over?
so you have the full kit for the 08. ign switch. CDI. fuse box. handle bar controls.
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post #9 of 10 (permalink) Old 1-21-2020, 7:29 PM
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Quote:
Originally Posted by yorkie View Post
doesn't need to just use the 454 front drive for the belt
Yes, but the transmission output shaft between the EX with a chain drive is different from older ENs and 454s with a belt drive. The front pulley for a belt will not simply bolt to an 08 EX engine.

Reference the attached photos. The much longer output shaft is the EN one, meant for a pulley. Attaching that pulley on the EX (with the much shorter output shaft) would be difficult.

Theoretically you could split the engine apart and swap the EN output shaft into the EX transmission.
Attached Images
File Type: jpg EX500 transmission.jpg (305.9 KB, 3 views)
File Type: jpg EN500 transmission.jpg (271.0 KB, 4 views)
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post #10 of 10 (permalink) Old 1-21-2020, 8:50 PM
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Quote:
Originally Posted by Brimstone View Post
Yes, but the transmission output shaft between the EX with a chain drive is different from older ENs and 454s with a belt drive. The front pulley for a belt will not simply bolt to an 08 EX engine.

Reference the attached photos. The much longer output shaft is the EN one, meant for a pulley. Attaching that pulley on the EX (with the much shorter output shaft) would be difficult.

Theoretically you could split the engine apart and swap the EN output shaft into the EX transmission.
I could not say how it was done but I have read on the 454 forum that is possible and often done as the 454 are now getting really old fitting the later gen 2 EX or EN 500 is a way of extending the bikes life I know they still use the belt and not the chain as there is no sprocket the right size for the rear hub in either 520 or 525 chain maybe it could be possible to drill out the centre so a circlip could be used to hold the drive on don't know really.
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