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Glover21

2007 Honda TRX420TM headlight problems

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I have a 2007 Honda rancher 2wd manual shift. Headlights nor tail light will come on until one of the hand brakes and the foot brake are pressed simultaneously. My brake light will come on with just the press of the foot brake. While holding the foot brake down and pulling my hand brake i can flick the lights from low to high beam and also turn them off and on. As soon as I let off the front brake (while holding the foot brake down) the lights go off. I've been told by several people this is a ground issue, however I have checked the grounds running to the frame and the block which have no corrosion. Any ideas ?? Thanks in advance!

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Welcome aboard.   Try unplugging the foot brake switch from the harness and see if it changes anything?  

 

If you download the factory service manual from the toolbar at the top of the forum home page, there are wiring diagrams in the back of the manual.   You can trace the wires from the headlight switch and see where the ground ties in vs the ground for your brake light switches on the foot brake and hand lever microswitches.

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Update.

So I believe the issue is coming from what is referred to as the big green 10 pin connector which is located between the handlebars and radiator. I pressed on it firmly, lights came on and stayed on for a few minutes but finally went back off as if a bad connection in that plug. Took it apart cleaned some corrosion on the inside then reconnected it. They still won't come on unless you squeeze the male and female connector together. Replacing the female end won't be bad as it comes from the ignition switch, however the male end comes straight off of the main harness. Do you think a new switch assembly w/ female connector would fix it or does it sound like the wires need to be spliced ??

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2 hours ago, Glover21 said:

Update.

So I believe the issue is coming from what is referred to as the big green 10 pin connector which is located between the handlebars and radiator. I pressed on it firmly, lights came on and stayed on for a few minutes but finally went back off as if a bad connection in that plug. Took it apart cleaned some corrosion on the inside then reconnected it. They still won't come on unless you squeeze the male and female connector together. Replacing the female end won't be bad as it comes from the ignition switch, however the male end comes straight off of the main harness. Do you think a new switch assembly w/ female connector would fix it or does it sound like the wires need to be spliced ??

 

I'd try cleaning again, and plugging and unplgging the connector several times.  If that doesn't do it, get a zip tie and press it firmly together, and then zip tie it to keep it pressed firmly together.

 

Or cut the appropriate wires from the connector and just put them together with butt connectors.

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