Hi, I'm having some trouble with my 1987 suzuki lt230s head light, it doesnt work at all. One night I was riding and it just shut off and then i tried it again and it went on and that was the last time it worked. I'm guessing wiring but i didnt kno if maybe there were some known problems. I know its 20 years old and things like this should be happening. but maybe some one could point me in the right direction as where i should attack this problem. Thanks a lot.

 

I don't know if I can shed any light on the subject, but I had the same problem with my 1987 LT230E. It ended up being the wiring. I ended up taking off all the plastic and opening up the whole wire harness. I found the problem as well as a few others just waiting to happen. I had to cut out some of the bad parts an solder in some new wires. At first I thought that it might have been a bad bulb or a bad switch, but both those checked out okay.

 

Thanks for replying, ya thats what im thinking too. i checked the bulb the next thing will be the switch. how much time did it take you to fix and were the cost relatively cheap?

 

It really didn't take too long. I just spent one saturday doing it. And I probably went overboard. I took the back rack, seat, front and rear plastics and the fuel tanks off. I then disconnected the whole wire harness and took it completly out. I unwrapped it and looked at every wire. I found some wires that had worn all the way through, some that were completly broken and some that were on their last leg. I cut out the bad wire and soldered in new wire. I then put the harness back in, put the fuel tank back on and fired it up. I wanted to make sure that everthing still worked before I got it all put back together. And it all did, so I finished putting it all back together. It didn't cost much at all. Just the soldering supplies, electrical tape, and some new wire. And I had all that stuff on hand, so it didn't cost me much of anything.

 

alright thanks for your help. ill have to clear out a day and do that work cause im sure theres more then one wire that should be replaced.

 

it might be the rectifier too but check the wiring first

 

Common for the switch to go bad on those, I have had 3 do so over the years[img]i/expressions/face-icon-small-sad.gif[/img]

 

Thanks for all the replies, what part is the rectifier? Ya I have a feeling it might be the switch, was replacing the switch hard and costly?

 

Back in the day, the dealership just hardwired the light to the 'on' position at the switch on my old '86 Qsport. I was just a kid then and said why not? I've been meaning to do that to this last switch that went out on the racer. Each time the switch has gone out on me, the lights work intermittantly but were mostly off. All it should cost you is a little time and solder, maybe a bit of wire.