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RG 250 Gamma Lighting System

Discussion in 'Suzuki 250cc 2 Strokes' started by MJP, Sep 11, 2013.

  1. MJP

    MJP Member

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    Hello All!
    Looking for some online assistance and came across this forum and would be grateful for any help!
    Owned and run the gamma for many, many, many years (it's still my daily transport) and it's just thrown the first problem that has me a bit stuck.
    Lost the headlight and high beam although side light still works. Replaced the bulb and have the same issue have I missed something simple like a fuse in the headlight wiring?

    Thanks again for any assistance,

    Matt
     
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Have the bulbs blown ? ..... look closely inside and usually u will see the filament "broken"

    Sounds more like loss of power to it though ..... I would doubt theres a specific fuse for the headlight.

    Check inside the bulb holder for corrosion on the the contact points and the surrounds inside.

    Then follow the wiring along its path looking for any kinks , breaks , rubbing and pull apart and check any connectors along the way.
     
  3. kiffsta

    kiffsta Senior Member

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    I found a bad scan of a wiring diagram, I would start at the bulb and work back from there, switch block maybe ?

    [​IMG]
     
  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    I found one in the manual and it has greasy fingerprints included! ..... I hate following wiring diagrams :commando:
     
  5. MJP

    MJP Member

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    Thanks for the fast replies. I didn't think there were many fuses on the system. Thought the bulb had just blown so got a replacement. The bulb holder and bulb are spotless and corrosion free. There are a lot of wires collected and packaged together immediately underneath the headlamp unit. As the problem only occurred following some seriously wet weather I'll get the fairing off and start in there. Look for connectors and get the electrical switch cleaner out! Don't think it's a switch problem as the light switch is mounted on the right but the passing/flash switch is on left and neither now work. All other lights/gauges/switches are working fine. Cheers Matt
     
  6. MJP

    MJP Member

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    Much fun later - found a fried wire sorted that now got the headlight passing/flash to work but not the headlight low or high beam so know the bulb is good and there is power at the headlight so now focusing on the headlight switch & the wiring from the switch. So many wires... so little room... takes so long... and a badly rounded screw head on the throttle wont budge so cant get into the headlight switch just yet. Having fun now :)

    Was trying to post some pics but files too large? Is there a file size limit?
     
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  7. MJP

    MJP Member

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    Wow time flies! I've been a bit slack but just this last month had a major push forward as the Gamma is up for it's MOT (Annual roadworthy/inspection/another government tax scheme) and I like to ride. Headlight issue resolved :imtheking: I identified the problem was at the switch. Messed around "gently" for ages trying to see what was going on and re-soldering the beautiful tiny factory connections that are assembled on the bench and not whilst the cable is dangling from the handle bars cos you don't want to disturb anything else!
    This didn't help.
    So having decided it was broken anyway I opened it right up. Had to be a little forceful seperating 28 year old plastic pieces but it all popped out exposing the little plastic slide with the copper switch connectors. This was all dirty and green so a good polish and back it went in.
    This didn't help.
    So now really brave and thinking of seeking a replacement switch I was seduced by my still warm and brand new soldering iron and got to thinking.... I had a good live into the switch and a good connection from the switch to the headlight unit. I tested the connection across the two on the fixed (non-slidy) side of the switch and I saw the light!:dance2: Solder these together by-passing the slide and Happy Days.
    All working fine the headlight is now ignition live so that's not a bad thing and main beam and passing flash are all good. Still have to operate the switch to turn on the rear light but that should all be legal enough.
    Now it would be nice to have it all as it should be so I will seek a replacement switch unit in the future but no rush.

    Leaky fork seals & Rear Brake Calliper: Well if you're going in there........ replacing all the fork components was probably a job too far for me and the space and equipment I have. So she's into the shop on in a couple of days I have sourced and supplied all brand new Suzuki Parts and whilst they have her they may as well do the rear calliper at the same time. A little lazy maybe but that should be that.

    While she's been naked the fairing sections have had all the oil/grease/dirt of the years removed inside and out with many layers of wax applied to the paint. A few little fibre-glass reinforcements to some weak and stressed areas and a couple of little splits patched on the inside and sitting ready to go back on.

    Wish list for the remaining projects:

    1. Replace fuel and oil lines with new before any problems occur.
    2. Similar Calliper refurb for the front - although this is problem free at the moment
    3. And the big one... replace or refurb the rear shock

    Get some summer fun road time in first, burn some 2-stroke oil and surprise a few people out at the gathering points with a beautiful old machine - Must get some photo's up!

    Happy and safe riding to all and thanks for the forum and all the help,

    Matt :drinks:
     
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  8. kiffsta

    kiffsta Senior Member

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    Yep, 1024 x 768 so it displays well on the forum, good to see you have sorted it.

    Cheers

    Chris
     

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