SX200 lighting problem

[GFSX200]

Hi Everyone,
This is my first time on the forum so hopefully this is in the right area.

I have a 1967 SX200 (our family from new). We restored it full nearly 15 years ago (saved from an uncles skip...), Its all standard apart from the Scooter Restorations electronic kit and loom (no battery). Here is the problem:

When you have the lights on in dip position they all work including the brake light and horn but when you flick to main beam we lose the side light and rear light although the brake light still works. Initially I thought the switch (casa) was to blame as if you rocked it slightly in the main beam position the lights would be ok.

I got a new switch from SR (one of their excellent quality ones...?) and now the problems is till there, lack of side and back light on main beam. I've since changed the headlight bulb holder/junction, cleaned all earths and replaced the rear light unit, checked all the wiring - still no joy!

Can you help its driving me mad!

[Knowledge]

Welcome to the forum.

You seem to have done the right sort of thing. Swapping the switch seems like the correct course of action, but the results have been disappointing.

I suspect a short circuit or bad connection somewhere. Somewhere these can lurk in the most unexpected places; even within the headlight or tail light bulb. These are cheap items to swap-out: much cheaper than a swapping out light switches.

Martin

[CHRIS in MARGATE]

A disconnected earth can cause similar.
I will check circuit diagram and see if I can expand on my thinking.

[Wack]

Make up a test bulb holder or use a multimeter with a buzzer. Connect one end to the red ( high beam) wire the other to earth and the buzzer should work with the switch in that position. If not then the problem has to be the switch or the wire, if it buzzes then the bulb holder must be faulty.

[MK Monty]

did you replace the ignition key switch or the dip/full beam and horn switch

[GFSX200]

To answer some of your replies I have not replaced the ignition key switch just the 'button' switch on the handlebar.
I will revisit all the earth connections and go over all of the wiring connections again, I'll also try the multimeter and buzzer trick as suggested.

Thank you all for your time and knowledge!

[grandpa]

Hi
Could be faulty headlight Bulb as knowledge suggests.does the rear light and pilot light work with the headlamp bulb removed.Try a separate length of wire on the metal case of bulb to frame ground to eliminate the bulb holder earthing
Good luck
Grandpa

[Captain Pugwash]

Have you fixed it yet Was it a crossed wire

[CHRIS in MARGATE]

Have you got Bilko there helping ? Lol