buddy
Expert Class
Posts: 335
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posted June 30, 2006 09:20 AM
I had the headlight problem and found it (after much studying of the schematics) to be a white wire under the seat and gas tank had come unplugged.
  
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VincentHill
Needs a life
Posts: 6520
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posted June 30, 2006 10:30 AM
quote:
I had the headlight problem and found it (after much studying of the schematics) to be a white wire under the seat and gas tank had come unplugged.
WOW! Finally an Actual Answer and know cure (At least one fix)! I have seen that wire and of all things would have never "Connected" to a headlight! (Pun intended) 
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Made History @ Daytona and still one fast old man!!
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BROOKLYNNYZX12
Zone Head
Posts: 520
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posted June 30, 2006 11:42 AM
I think the white wire is part of the stator bundle of wires...maybe a lookee there will help.I think its under the tank on the back of the engine...not the easiest place to get to.Maybe oil has crept into that connector.
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Orient Express Top Street Bike Winner 8-4-07
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oldkawboy
Needs a job
Posts: 2125
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posted July 01, 2006 03:04 PM
Had a chance to trouble-shoot today, still no luck.
I found the white connector both in person and in the schematic. I checked the alternator output again, this time all the way to that connector & all three phases read 115v again @ 4k rpm.
I checked from that connector to the j-box and it was good. Re-checked the j-box by the manual using a battery and without and it tested good.
Thanks again guys for the suggestions, I'm finding everything it ain't !!
Dan
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aughtsix
Expert Class
Posts: 277
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posted July 01, 2006 04:23 PM
 Edited By: aughtsix on 1 Jul 2006 17:26
Dan - This is all weirdly familiar...
You say you've swapped out the junction box, and I hate to ask, but was it a known good unit?
Someone on .org had the same problem, went through all the same steps, even testing the junction box which, if I recall correctly, came out fine like yours has. I think the guy was about to torch the whole mess until someone else sent him a known good junction box, he figured he had nothing to lose by tring it and that fixed the problem.
Sometimes I wish I'd link threads like this - just in case...
Edit - I just re-read your initial post and you said it was a known good unit. Never mind... 
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rac4it
Needs a job
Bergie
Posts: 3009
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posted July 01, 2006 05:56 PM
hard wire that shit and trade it in on a ZX14
problem solved!
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Wideout
Expert Class
Posts: 300
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posted July 01, 2006 06:10 PM
Edited By: Wideout on 1 Jul 2006 19:12
That thread is currently on the 1st page of the 12r section at the org.
I have an extra known good j-box if gunner doesn't. Share your knowledge when I'm in need and I'll send it to you for free.
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jay
Parking Attendant
Posts: 9
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posted March 20, 2009 05:05 PM
so what was the fix?
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oldkawboy
Needs a job
Posts: 2125
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posted March 20, 2009 07:15 PM
Wow, this goes back almost three years.
I never found out what the problem was. After getting frustrated to death I took the bike to a local dealership & they contacted Kawasaki and let them know the bike had the recall done on the stator / rectifier connection.
I about passed out when they replaced the stator, wiring harness, rectifier & junction box all at no charge. The bike was 6 years old with no extended warranty.
Needless to say I was impressed and thankful that Kawi stepped up.
Dan
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whitehendrix
Zone Head
fails!
Posts: 757
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posted March 20, 2009 11:28 PM
those junction boxes are whores.. they use that SAME exact one on all the 90's and early 2000's 600s, the 7-R the nomad and other cruisers, the 12-R, ZX-11, ZZR's.. just about everything.
i'm working on a solid state conversion for my 7 to take out the MR301 relays and replace them with something fail-proof.. gotta find a compatible relay. the MR301 form 1C relay was a special-made relay with (for some stupid reason) a 9V coil and regular old dry contacts like a mass-produced commercially available unit. not sure if that particular one had any more kawi-specific tweaks, but i know theres a SS relay available. just gotta find it.
my 7 won't start sometimes.. a little rap on the black box kicks her right over.. lol the contact life is supposed to be 1 million cycles and almost o contact bounce..
no clue as to why they fail tho. the headlight relay is the exact same relay as the starter solenoid control power relay. they're both the MR301 relay i've come to know and loathe.
wierd shit about the headlight tho.
____________
Duct tape is the handyman's secret
weapon. The black is for formal
occasions. - ZRXDean
ill never own a busa unless
someone gives me one.... and then
ill sell it -KZScott
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Rock4173
Novice Class
Posts: 43
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posted March 25, 2009 10:53 AM
Just a thought I had the same problem on my 2001 zx9. I changed the fuse box with no change after a few days of deep thought I changed the voltage regulator and that fixed it. This all happened 4 years ago no problem since.
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Kurrupt1
Parking Attendant
Posts: 1
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posted July 22, 2009 08:01 PM
I have had the same problem as all and it went out again tonight after I put in a new J-box before it was a burn wire going to j-box I think the horn, again tonight I just don't know, so tired of this mess!! light out again. Did they have a recall on this problem?
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Kurrupt1
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Rock4173
Novice Class
Posts: 43
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posted August 19, 2009 07:59 AM
I guess I have the black cloud following me around, because the headlights on my 2000 ZX12 went out last week after a short ride went back to start it to go home and no lights. I had lights when I parked it. I know this because I was in a prking garage. As stated before I had the same problem on my 2001 ZX9. Its begining to be a large pain in the......
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Rock4173
Novice Class
Posts: 43
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posted August 24, 2009 06:06 AM
I was lucky on this one it was only the fuse in the battery compartment.
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maddfayce
Novice Class
SARR SGT@ARMS
Posts: 47
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posted October 09, 2009 04:47 PM
Edited By: maddfayce on 10 Oct 2009 00:47
Well my battery went dead on my bike. Installed a brand new battery and now the headlights dont work. Checked the fuses and all the grounds. Not sure where to look for the relays to check or how I would hardwire it. Bulbs are good still.
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maddfayce
Novice Class
SARR SGT@ARMS
Posts: 47
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posted October 12, 2009 01:44 PM
I rode it during the daytime and the battery went dead. I am now guessing its either the stator or the rectifier.
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maddfayce
Novice Class
SARR SGT@ARMS
Posts: 47
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posted October 29, 2009 07:40 PM
Ok, I changed the stator, rectifier and reinstalled the new battery. I took out the two relays behind the gauges and they both had a multitude of dead spiders and their webs in them. Could that make the headlights go out with a bad connection in there? The right front turn signal just went out as well.
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maddfayce
Novice Class
SARR SGT@ARMS
Posts: 47
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posted November 05, 2009 03:39 AM
Ok, I took every relay off the bike, recharged the battery (again), took all the fuses out and took the J Box apart to look at the relays on the back, put it all back together and the right turn signal works again, but still no headlights. Would this headlight issue be related to the BRAND NEW stator not charging the battery?
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entropy
Moderator
Posts: 8671
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posted November 05, 2009 04:53 AM
have you jumped past the relays in the junction box to assure it is not the culprit?
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This moderator uses moderation in moderation
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MAXIMUS
Needs a job
Posts: 4156
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posted November 07, 2009 08:56 AM
Get yourself the schematic , the fuse for the head lights is located in the junction box/fuse box. You can get yourself a relay at your local electrical supply store, get yourself a low wattage soldering iron and replace the relay.
Just get the numbers off the old relay, Someone posted up the schematics on this forum a few years ago, I am sure if you research it a little you can still find them.
Good luck.
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