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Headlight switch on CL77

Charging System, Wiring, Lighting
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ggray Member
Posts: 314
Joined: Tue Jun 27, 2006 6:14 pm
Location: Joplin, Mo.

Headlight switch on CL77

Post by ggray » Tue Jun 10, 2008 4:20 pm

OK, Been having a problem with my headlight switch on my '65 CL77.

When ignition switch is in the run position and in neutral, I get a neutral indicator light.

This is with the healight switch in the center, or "Off" position.

If I turn the headlight switch clockwise to position II, the neutral light goes out and I only get about 6v throught the brown wire coming out of the headlight switch. (This is the hot wire that goes to the dimmer switch mounted on the handle bars). Also, this happens with the brown wire NOT connected to the lead from the dimmer switch.

And this happens even if I have the headlight itself is disconnected from the red and blue wires for dim and bright.

I have checked continuity of the wires coming out of the dimmer switch and have good continuity between the brown (Hot) wire and the red and blue wires at each dimmer switch position so I am relatively sure the dimmer switch is working properly.

Is it possible I have a bad headlight switch?

All bike functions work properly if I have the headlight switch in the "Off" position and only have a problem when I turn the headlight on to position II.

Any ideas?


'65 CL77 Owner

splitenz Member
Posts: 104
Joined: Sun Jun 03, 2007 1:16 pm
Location: cleveland ohio

Post by splitenz » Wed Jun 11, 2008 8:53 pm

got my curiosity, do I hear "short" somewhere? I am new to this so I ask exactly how is this supposed to work, with the headlight and the handlebar dimmer switch? thx.
'63 CL72

ggray Member
Posts: 314
Joined: Tue Jun 27, 2006 6:14 pm
Location: Joplin, Mo.

Headlight switch.

Post by ggray » Wed Jun 11, 2008 10:00 pm


On a CL the brown wire coming out of the HL switch feeds 12v to the handlebar dimmer switch. Dimmer switch controls whether power goes to the main beam or the high beam.


To all other members:

Through a process of going through each wire coming from the HL switch, I've found that by unplugging the green wire, my headlight works and does not cause the neutral light to dim or go out and both beams of the headlamp work.

Does anyone know exactly what the green wire, coming from the "ML" position on the HL switch controls?? According to my schematic, It plugs into the green wire on the main harness originating from the ignition switch. If everything works with this green wire unplugged, would there be any ill effects by leaving it unplugged?

Thanks, Gary
'65 CL77 Owner

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davomoto Member
Posts: 2508
Joined: Sat Nov 18, 2006 7:36 pm
Location: Marin County CA

Post by davomoto » Thu Jun 12, 2008 3:57 pm

Gary the green wire coming from the harness should have a 4 way plug. It plugs to the headlight switch, and the dash lights. There is also a grenn wire with a white plastic piece, that is headlight ground, and speedo ground. If all of that is connected properly, perhaps one of your speedo lights is grounding out?


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