Headlights not working

[chris71920]

Basically if I turn the switch 1 click I get sidelights and rear lights no problem. If I switch to headlights (dip) I still only get rear lights but nothing up front! Also flashing and full beam do nothing.

Is it likely to be the switch in the stalk or something else? Ive checked all fuses and none have blown

[Darrell]

I'm going to say disconnect the battery and unscrew the fuse box. Have a look on the back as part of the unit sometimes burns out. This link can be fixed by just soldering a suitable wire in place. Other than that, the stalk. But that sounds bloody fiddly so I would check the fusebox first

Circuit diagram just in case you have to get the multimeter out.........

[ROBBIE]

I had this problem on mine. It was caused by smoke coming out of the dash easy fix new wire and switch on the dash

[Tramp]

I can't find the pictures now but on mine the wire that crimps to the fuse holder had burnt up (i had the wrong bulbs in) you could see where because it had discoloured the plastic around the fuse

[Darrell]

Did you fix them ?
If so what was wrong with them

[chris71920]

Not had a chance to look at them yet tbh lol Been too busy pi$$ing about with the Weber and its general running and also sorting the rear shock mounts out at a better angle

Will investigate soon, thanks for the replies guys

[chris71920]

Whipped the fusebox off today and theres definately some "burning" going on, as you can here.....Is this where and what you were referring to earlier?

[Darrell]

Well I have heard of some of the fuse board burning up/out, but yours looks just the same as Tramp describes. Poor connection between the fuse board and the push on connection block. Poor connection creates resistance which creates heat and as you can see that's got blooming hot.
I must admit your fusebox is not the same as mine (Jap). Is yours a Spanish build ?.
Thanks for posting the pics up

[chris71920]

Very different indeed! Its a '92 Samurai so im guessing it is...

Hmmm, is this likely to be the cause of the headlight failure?

[Tramp]

Hmmm, is this likely to be the cause of the headlight failure?

Yes!

Mine was exactly the same in the same place! instead of them not working mine became lazy, not starting up straight away but after a few seconds until they stopped working alltogether. I cleaned up the connection using fine emery, built up the pcb with a bit of solder and seperated the crimp from the plug and cleaned it using more fine emery paper, I then put the original size bulbs back in and it worked....

Yes your fuse box is the standard Spanish one the same as my 92 sammy

P.s I had a look for photos but difflocks genocide of images last year appears to have earased mine including my pics of the switchgear clean up

P.p.s you could probably get away with just cleaning up the plug and the pcb board, I went a little over the top when I did mine