MAXIMUS
Needs a job
Posts: 4156
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posted May 19, 2007 08:49 PM
Headlights?
Does anyone have a copy of the headlight wiring diagram for 2003 zx12r, my headlights just stop working, all other lights are working fine. the third bulb above the headlights also quit working, I am thinking a bad connector somewhere. all fuses test good at the fuse box.
  
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Texas12R
Zone Head
Posts: 545
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posted May 19, 2007 09:58 PM
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Texas12R
Zone Head
Posts: 545
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posted May 20, 2007 07:12 AM
Well I didnt say I was the sharpest knife in the drawer
2003=B2 model
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lgm118icbm
Novice Class
Posts: 48
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posted May 21, 2007 05:55 AM
check the fuse by the battery, other than that it might be the relay.
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Costa Mesa, Ca
03 ZX-12R
03 Z-1000SC
04 ZX-6R
98 Concours
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maximus
Needs a job
Posts: 4156
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posted May 28, 2007 03:29 PM
It was the relay but the relay is in the junction box, sad part is the relay is part of the circuit board in the junction box, I believe it be a very stupid design. You have buy a whole new junction box to replace it, I opened it up and bypassed the relay, it only controls the lights on starting, it kills them to try and reserve as much battery power as possible. Now that it is bypassed the light come on as soon as I turn the ignition switch on.
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tuusinii
Pro
Posts: 1031
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posted May 28, 2007 10:42 PM
There is a thread dealing with this and in it there are instructions how to change teh relay. You can get a new one from radio shack or somewhere else - was about 5$.
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maximus
Needs a job
Posts: 4156
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posted May 29, 2007 06:27 AM
I just bypassed and all is working good, rode the bike all weekend and had no starting problems.
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Rock4173
Novice Class
Posts: 43
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posted August 19, 2009 07:14 AM
Did you happen to take pictures as you were working on it. I have a 2000 and the lights just didn't come back on after a short ride. All other lights work fine even park light. I swapped the fuse box with my 2001 zx9 and no change.
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Rock4173
Novice Class
Posts: 43
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posted August 24, 2009 06:08 AM
It was the fuse in the battery compartment. I guess it just got to hot and blew
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thekaz
Needs a job
spell chequer is bustimicated
Posts: 2909
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posted August 24, 2009 10:08 AM
Just solder a new relay in the board ?
not a hard task at ALL 
When it starts snowing over there take it apart and send it my way . I can do it for beer 
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MAXIMUS
Needs a job
Posts: 4156
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posted September 06, 2009 07:26 PM
I had to buy a relay at the local elec supply shop and soldered it to the board and all my problems were solved.
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