dougmeyer
Needs a job
moderated
Posts: 2713
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posted August 24, 2008 11:33 AM
Headlights dead- I need your suggestions!
A couple weeks ago my battery went dead and I replaced it with new. Shortly thereafter I found my headllights were not working. Since then I have checked or changed:
Headlight 20A main fuse
Headlight 10 A junction block fuse
Headlight circuit relay
High / Low beam relay
Battery tray connections
Harness connectors
All relevant plug pins
Both bulbs
All other electrical functions and all lights are normal. Anybody got an idea? I'm out.
I will swap the ECU but haven't yet.
Doug
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It's not that I think you're dumb, it's just that so much of what you know isn't true....
  
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KZScott
Needs a life
high on speed
Posts: 7235
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posted August 24, 2008 11:49 AM
Doug, this may be a little basic for someone like you, but this thread may point out something you may have missed?
http://zx-12r.org/zx-12r-forum/28775-stator-connector-no-headligths-fix-new-pics.html
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01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted August 24, 2008 06:19 PM
On the contrary! I had forgot all about the fact that the headlight circuit goes through that plug, which on my bike is original. I bet that's it.
THANKS KZ
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It's not that I think you're dumb, it's just that so much of what you know isn't true....
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KZScott
Needs a life
high on speed
Posts: 7235
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posted August 24, 2008 06:47 PM
happy to help 
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01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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entropy
Moderator
Posts: 8671
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posted August 24, 2008 09:36 PM
doug,
the plug near the rectifier sux, but replacing the junction box it self or just the relay inside (for the adept solderers) fixed mine.
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zx12mark
Pro
Posts: 1654
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posted August 27, 2008 10:15 PM
doug, i had cold soilder broken connections on my 91 zx11 ign.key harness.it caused me all kinds of trouble for 2 years till i found that sucker.man did the bike run good after that repair.
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted September 08, 2008 10:17 PM
UPDATE!
Well, I fixed it but I sure took the long way around.I had a clue and should have known better but I ignored it. Stupid.
In the course troubleshooting this deal I replaced the external headlight relay, the relay soldered into the j-box, the reg/rect plug, and swapped out the ECU. It wasn't unitil I did all that without any result that I decided to check the alternator and rectifier values. The rectifer was fine but the alternator was TOAST- completely shorted.
Here's the dumb part-
One of the first rules of chasing a problem that just "shows up" is to go back to the last thing you touched before you noticed the problem. I noticed that my lights were out just after I replaced a suddenly dead battery. HELLO.... Why did my battery die?, I should have asked.
If I had started the troubleshooting process at the causal end instead of the result end, I would have saved a hell of a lot of work.
I owe KZ scott a big thank you for reminding me of that 12 volt head light power supply wire in the Alt. harness plug, which put me on the right track, but it still took me too long to get around to checking the alternator. When I went to my spares I found that I had spare stator, which I had ordered in 2000 to take to Bonneville with me. Forgot all about it.
All in all, a good lesson.
Doug
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It's not that I think you're dumb, it's just that so much of what you know isn't true....
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