Well i finally got fed up with my headlight problems and random vibrations from the front of the bike at the magical 4500ish rpms.
Anyways over the past OH 2 months i have had problems with my headlight going out, it was always a simple fix associated with a broken solder joint on the starter button... as the starter button cuts the headlight power when you press it.
So the first time it happened i just re-soldered it and it lasted for about 3 weeks. I then went on a ride in which i did about 15mi or so off road on a dirt trail... (yes on my 919... ppl look at me weird), and the next day a buddy and i went out for a dusk ride... mid ride just before dark headlight goes out... and i dont have a screw driver to get into the throttle housing or headlight housing
needless to say i rode home without a light invisible as fuck (buddy did ride close in front of my to be my headlight... even then i was still invisible)
So the second time around i resoldered it, and put hot glue on top in hopes that would reduce vibrations and resolve the solder breaking issue.... well yesterday it happened again, and i said EFF IT. i cut the wire clean up in the throttle housing... then down on the plug side in headlight housing i simply wired the two headlight wires together permanently, so when the key is on, the headlight is on. even when starting... tbh there is ZERO issue with this... a headlight draws 4-5amps on low beam... starter 100a + ... the extra 4amp draw isnt going to cause any starting issues and it doesnt, the bike cranks over just as quick as it always has. and i dont have to worry about being stranded without a headlight again (theres a reason why baja guys always run at least two!!!)
Anyways onto the pics.
Here is the wires to the starter switch with its broken solder joint... at this point i had cut the wire clean
Down at the plug end of the pigtail from the throttle housing i cut the two wires for the headlight, pulled the pins out of the plug, n soldered them up.
Some shrink wrap and pins back into the plug later
Walla, always on headlight... no more issues with no headlight.
ALSO while i was at it i redid the beauty ring on the headlight. the chrome ring that goes over the glass is held on by three tabs and was held in place by 3 globs of silicone.... which had all come undone. SO i ran a bead of clear rtv silicone around the front face of the headlight, and side, so there is no way that the ring could vibrate. I also put some electrical tape on the surfaces of the plastic housing where it mates with the main chrome headlight holder to get rid of vibrations. I havnt tested it yet but im sure vibrations will be gone. Also while i was at it i used a lil of the clear rtv on the surfaces that would cause vibration noise on the radiator guard.
This is the ring im talking about.