No headlights...

And no engine start unless i remove what I believe is the headlight fuse. Any thoughts?

 

A pic of what you removed and the location may help in diagnosis.

How's your battery?

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Fuse f is for headlights i think.Battery is fine.

 

voltage to headlight goes through contacts in the START pushbutton.

 

Here is what happens,I turn the key to on position and no headlights or fuel pump goes on.I push the start button, engine starts and stops when I let go of the button. I remove the fuse for the headlights and fuel pump runs normally and engine runs fine. No headlights of course.

 

Have you tried replacing the headlight fuse with a new fuse?

Then I'd clean the start switch

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I have tried a new fuse,no change.I will clean the start switch. Thank you.

 

Problem is with ground wire behind the cowl,also I have no lightning switch?

 

I found the cause.Too much load for the ground wire.

 

Toasty!

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Lights are working again.

 

they did it again !? honda often routes a single ground wire to return electrons from several components rather than using more grounds, causing overheating and failure. they always needed better electrical engineers on staff.

later models (after '99) are worse cuz they used smaller-diameter wires !

 

Bike now has a second ground wire going back to near the battery.