Zx12r headlight issue - Kawasaki Forum :: KawasakiWorld.com
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post #1 of 14 Unread 11-23-2019, 10:29 PM Thread Starter
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Zx12r headlight issue

Alright guys i finally got hit with the headlight issue. (None at all other the city bulb) i hardwired my fan a couple months ago untill the new switch got here and put it back with no issues. Checked all fuses and relays all good and the high beam indicator on the cluster dosent light up as well when i hit the the switch if that means anything to anyone. Im pulling my hair out over this please help!!!!!!
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post #2 of 14 Unread 11-24-2019, 03:34 AM
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Right, I believe you have a zx12 A1 USA model, going by your avatar and location.

Do you know how to use a multimeter?

Gain access to the fuse box, get your multimeter out set it to 200volt AC unless it's an auto one then just select AC that's the wavy line, not the flat line. Now with the engine running put the black negative lead to a clean part of the frame or engine and put the red positive lead to the Yellow wire in the fuse box. Check for an AC voltage above 12 volts.

If this voltage is there, then Its time to remove the fuse box and get the diodes inside checked and or replaced.

If the voltage is not there, you will need to lift the tank and trace the yellow wire to where it goes into a plug and then comes out on the other side as a White wire. This White wire is tapped off from one of the white wires coming up from the stator to the regulator, so you can unplug the regulator and use this plug to do resistance checks to the plug brake you found earlier. You will be looking for zero resistance, 1.5 Ohms ish will be because you're checking through the stator to it, 2 of the regulator plug wires should read this and the correct one will/should read zero saying its ok.

A junction fuse box testing how to with pictures can be found here. https://www.zx-9r.net/viewtopic.php?f=48&t=59052 zx9 and zx12 use the same fuse box in the states with only fuse sizes changing for the zx12r B's with 2 fans.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 11-24-2019 at 03:38 AM.
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post #3 of 14 Unread 11-24-2019, 03:42 AM
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Fuse boxes should be easy to find a cheap replacement.

ASSEMBLIES WHERE 26021-1096 IS USED
1995 GPZ1100 (ZX1100-E1) - Chassis Electrical Equipment
1996 GPZ1100 (ZX1100-E2) - Chassis Electrical Equipment
1996 GPZ1100 ABS (ZX1100-F1) - Chassis Electrical Equipment
1996 NINJA ZX-7R (ZX750-P1) - Chassis Electrical Equipment
1996 NINJA ZX-7RR (ZX750-N1) - Chassis Electrical Equipment
1997 GPZ1100 (ZX1100-E3) - Chassis Electrical Equipment
1997 NINJA ZX-7R (ZX750-P2) - Chassis Electrical Equipment
1997 NINJA ZX-7RR (ZX750-N2) - Chassis Electrical Equipment
1998 NINJA ZX-6R (ZX600-G1) - Chassis Electrical Equipment
1998 NINJA ZX-7R (ZX750-P3) - Chassis Electrical Equipment
1998 NINJA ZX-9R (ZX900-C1) - Chassis Electrical Equipment
1999 NINJA ZX-6R (ZX600-G2) - Chassis Electrical Equipment
1999 NINJA ZX-7R (ZX750-P4) - Chassis Electrical Equipment
1999 NINJA ZX-9R (ZX900-C2) - Chassis Electrical Equipment
1999 VULCAN 1500 DRIFTER (VN1500-J1) - Chassis Electrical Equipment
1999 VULCAN 800 DRIFTER (VN800-C1) - Chassis Electrical Equipment
1999 ZRX1100 (ZR1100-C3) - Chassis Electrical Equipment
2000 NINJA ZX-6R (ZX600-J1) - Chassis Electrical Equipment
2000 NINJA ZX-7R (ZX750-P5) - Chassis Electrical Equipment
2000 NINJA ZX-9R (ZX900-E1) - Chassis Electrical Equipment
2000 VULCAN 1500 CLASSIC FI (VN1500-N1) - Chassis Electrical Equipment
2000 VULCAN 1500 DRIFTER (VN1500-J2) - Chassis Electrical Equipment
2000 VULCAN 1500 NOMAD FI (VN1500-L1) - Chassis Electrical Equipment
2000 VULCAN 800 DRIFTER (VN800-C2) - Chassis Electrical Equipment
2000 W650 (EJ650-A2) - Chassis Electrical Equipment
2000 ZRX1100 (ZR1100-C4) - Chassis Electrical Equipment
2001 NINJA ZX-6R (ZX600-J2) - Chassis Electrical Equipment
2001 NINJA ZX-7R (ZX750-P6) - Chassis Electrical Equipment
2001 NINJA ZX-9R (ZX900-E2) - Chassis Electrical Equipment
2001 VULCAN 1500 CLASSIC FI (VN1500-N2) - Chassis Electrical Equipment
2001 VULCAN 800 DRIFTER (VN800-E1) - Chassis Electrical Equipment
2001 W650 (EJ650-A3) - Chassis Electrical Equipment
2001 ZRX1200R (ZR1200-A1) - Chassis Electrical Equipment
2002 NINJA ZX-6R (ZX600-J3) - Chassis Electrical Equipment
2002 NINJA ZX-7R (ZX750-P7) - Chassis Electrical Equipment
2002 NINJA ZX-9R (ZX900-F1) - Chassis Electrical Equipment
2002 VULCAN 1500 CLASSIC FI (VN1500-N3) - Chassis Electrical Equipment
2002 VULCAN 800 DRIFTER (VN800-E2) - Chassis Electrical Equipment
2002 W650 (EJ650-A4) - Chassis Electrical Equipment
2002 ZRX1200R (ZR1200-A2) - Chassis Electrical Equipment
2003 NINJA ZX-7R (ZX750-P8) - Chassis Electrical Equipment
2003 NINJA ZX-9R (ZX900-F2) - Chassis Electrical Equipment
2003 VULCAN 800 DRIFTER (VN800-E3) - Chassis Electrical Equipment
2003 ZRX1200R (ZR1200-A3) - Chassis Electrical Equipment
2004 VULCAN 800 DRIFTER (VN800-E4) - Chassis Electrical Equipment
2004 ZRX1200R (ZR1200-A4) - Chassis Electrical Equipment
2005 VULCAN 800 DRIFTER (VN800-E5) - Chassis Electrical Equipment
2005 ZRX1200R (ZR1200-A5) - Chassis Electrical Equipment
2005 ZZR600 (ZX600-J4) - Chassis Electrical Equipment
2006 VULCAN 800 DRIFTER (VN800E6F) - Chassis Electrical Equipment
2006 ZZR600 (ZX600J6F) - Chassis Electrical Equipment
2007 ZZR600 (ZX600J7F) - Chassis Electrical Equipment
2008 ZZR600 (ZX600J8F) - Chassis Electrical Equipment

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #4 of 14 Unread 11-24-2019, 06:51 AM Thread Starter
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Yes it is an A1 and thanks for all the info!!!!! Ill try and play around with it later
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post #5 of 14 Unread 11-24-2019, 06:56 AM Thread Starter
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The yellow wire you are referring too...... is it on the fuse box under the tank cover or you talking about the couple on the batt. Tray?
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post #6 of 14 Unread 11-24-2019, 11:16 AM Thread Starter
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Ok so checked the only yellow wire coming out of the fuse box with the bike running and multimeter (snap on) set to AC voltage i was getting like 8 even ish. The bike is hardwired at the stator plug
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post #7 of 14 Unread 11-24-2019, 12:49 PM
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Ok to start with that yellow wire goes into the fuse box carrying an unregulated AC waveform, and on its positive cycle, it will go through a diode in the fuse box and then trip the headlight relay.
Once the headlight relay is tripped some of its output voltage to the headlight high low switch is tapped off and goes through another diode and holds its self in the energized ON state, otherwise, on the negative sweep of the tripping AC voltage from the stator it would de-energize the relay again.

These headlight relays in the fuse box can be finicky, some only need 5 volts, others won't trip on anything less than 10 volts, that's why I said to look for anything over 12 volts AC.

Now you could just quickly dab the battery voltage with a link wire onto the yellow wire to see if it will trip the headlight relay, but if you're not getting enough AC voltage you need to check that first. Personally, at this point I would pop out the fuse box open it up only 4 small screws and do a few tests on it.

Just go to the how-to on zx-9r .net, or would you prefer if I posted the whole content here.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #8 of 14 Unread 11-24-2019, 12:51 PM
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How to test a Kawasaki junction fuse box relays and some of the diodes that are used to trip them with a 9 volt battery, without having to open it up.

A New 9 volt battery is required so it has enough power to trip the relays and bias the diodes, but not enough power to blow anything.

Possible Relay Replacement seems ok but still needs more testing, as I want to see what voltage it will trip down to, I know a little 9volt battery will trip it so thats a good start. Search google or ebay for "HY3FF-DC12V"

Some of the junction boxes have 2 relays and we can check they both work.

You will need the diagram to show you the location of the numbered pins, and you will also be able to see what bits its checking.

You need to be in a fairly quite area so you can hear the relays tripping.

First thing to check is the starter interlock relay and diode by going between pins 11 positive (Red) and 12 negative (Black) You should hear the relay clicking over, Now reverse the wires and the relay should not be heard tripping, if you can then the diode is shorted and needs replacing, if you hear nothing reverse the wires back over again to make sure it still works.
If during the checks nothing can be heard the diode is either blown open circuit or the relay is blown or your battery is not new enough.

Second thing to check is the headlight relay if it has one and its 2 diodes, one diode is the trip diode and the other is the relay hold on diode. To start with go between pin 9 Positive (Red) and 13 negative (Black) you should hear the rally tripping, now reverse the wire and try again, if the relay still trips the diode is shorted and needs replacing, now switch back the wire and make sure the relay still works.
Now go between 8 positive (Red) and 13 negative (Black) and you should hear the relay tripping again, reverse the wires again and if the relay trips again the diode is shorted and needs replacing, switch back the wires and check the relay still works.
If during the headlight relay check the relay cannot be heard tripping at any time either both diodes are blown or the relay is blown or your battery is not new enough.

If you wanted to check the other inter lock diodes then you need to use a multimeter on the 2k Ohms range with the positive (Red) lead on pin 14 and the Negative (Black) lead on pins 12, 15 and 16 in turn. You should get a reading of about 750 Ohms, now reverse the leads and you should read open circuit on each pin. if you get open or short circuit on any test the diode needs replacing.

Good Luck.
yorkie

service manual information, but the overall diagram is all you need


starter interlock relay


headlight relay


relay only testing with the battery, you need a meter for the diodes or have the LED like I have in the pictures above

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #9 of 14 Unread 11-24-2019, 02:43 PM Thread Starter
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Thanks man really appreciate everything. I did give that yellow at the fuse box 12v from my power probe and still nothing. Double checked the relays under the cluster and they worked fine as per the manual. Havent done the 9v thing yet tho
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post #10 of 14 Unread 11-25-2019, 09:43 PM
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Before you beat yourself to death over the headlamps, how new is your battery?
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post #11 of 14 Unread 11-26-2019, 03:46 AM
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Hows it going?
More fuse boxes, these ones will have the same part number as the one you have fitted and the 10 AMP fuse fitted for the fan.
Not that the ones above won't work it's just they have a 15 AMP fan fuses for the later 2 fan 12's, the rest of the fuse box is the same apart from the part number and the fuse size rating on the underside of the fuse cover.

ASSEMBLIES WHERE 26021-1089 IS USED
1994 NINJA 500 (EX500-D1) - Chassis Electrical Equipment
1994 NINJA ZX-9R (ZX900-B1) - Chassis Electrical Equipment
1995 NINJA 250R (EX250-F9) - Chassis Electrical Equipment
1995 NINJA 500 (EX500-D2) - Chassis Electrical Equipment
1995 NINJA ZX-11 (ZX1100-D3) - Chassis Electrical Equipment
1995 NINJA ZX-6 (ZX600-E3) - Chassis Electrical Equipment
1995 NINJA ZX-6R (ZX600-F1) - Chassis Electrical Equipment
1995 NINJA ZX-7 (ZX750-L3) - Chassis Electrical Equipment
1995 NINJA ZX-9R (ZX900-B2) - Chassis Electrical Equipment
1995 VULCAN 800 (VN800-A1) - Chassis Electrical Equipment
1995 VULCAN 88 (VN1500-A9) - Chassis Electrical Equipment
1996 NINJA 250R (EX250-F10) - Chassis Electrical Equipment
1996 NINJA 500 (EX500-D3) - Chassis Electrical Equipment
1996 NINJA ZX-11 (ZX1100-D4) - Chassis Electrical Equipment
1996 NINJA ZX-6 (ZX600-E4) - Chassis Electrical Equipment
1996 NINJA ZX-6R (ZX600-F2) - Chassis Electrical Equipment
1996 NINJA ZX-9R (ZX900-B3) - Chassis Electrical Equipment
1996 VULCAN 1500 (VN1500-A10) - Chassis Electrical Equipment
1996 VULCAN 1500 CLASSIC (VN1500-D1) - Chassis Electrical Equipment
1996 VULCAN 1500L (VN1500-C3) - Chassis Electrical Equipment
1996 VULCAN 500 LTD (EN500-C1) - Chassis Electrical Equipment
1996 VULCAN 800 (VN800-A2) - Chassis Electrical Equipment
1996 VULCAN 800 CLASSIC (VN800-B1) - Chassis Electrical Equipment
1997 NINJA 250R (EX250-F11) - Chassis Electrical Equipment
1997 NINJA 500 (EX500-D4) - Chassis Electrical Equipment
1997 NINJA ZX-11 (ZX1100-D5) - Chassis Electrical Equipment
1997 NINJA ZX-6 (ZX600-E5) - Chassis Electrical Equipment
1997 NINJA ZX-6R (ZX600-F3) - Chassis Electrical Equipment
1997 NINJA ZX-9R (ZX900-B4) - Chassis Electrical Equipment
1997 VULCAN 1500 (VN1500-A11) - Chassis Electrical Equipment
1997 VULCAN 1500 CLASSIC (VN1500-D2) - Chassis Electrical Equipment
1997 VULCAN 1500L (VN1500-C4) - Chassis Electrical Equipment
1997 VULCAN 500 LTD (EN500-C2) - Chassis Electrical Equipment
1997 VULCAN 800 (VN800-A3) - Chassis Electrical Equipment
1997 VULCAN 800 CLASSIC (VN800-B2) - Chassis Electrical Equipment
1998 NINJA 250R (EX250-F12) - Chassis Electrical Equipment
1998 NINJA 500 (EX500-D5) - Chassis Electrical Equipment
1998 NINJA ZX-11 (ZX1100-D6) - Chassis Electrical Equipment
1998 NINJA ZX-6 (ZX600-E6) - Chassis Electrical Equipment
1998 VULCAN 1500 (VN1500-A12) - Chassis Electrical Equipment
1998 VULCAN 1500 CLASSIC (VN1500-E1) - Chassis Electrical Equipment
1998 VULCAN 500 LTD (EN500-C3) - Chassis Electrical Equipment
1998 VULCAN 800 (VN800-A4) - Chassis Electrical Equipment
1998 VULCAN 800 CLASSIC (VN800-B3) - Chassis Electrical Equipment
1999 NINJA 250R (EX250-F13) - Chassis Electrical Equipment
1999 NINJA 500 (EX500-D6) - Chassis Electrical Equipment
1999 NINJA ZX-11 (ZX1100-D7) - Chassis Electrical Equipment
1999 NINJA ZX-6 (ZX600-E7) - Chassis Electrical Equipment
1999 VULCAN 1500 (VN1500-A13) - Chassis Electrical Equipment
1999 VULCAN 1500 CLASSIC (VN1500-E2) - Chassis Electrical Equipment
1999 VULCAN 500 LTD (EN500-C4) - Chassis Electrical Equipment
1999 VULCAN 800 (VN800-A5) - Chassis Electrical Equipment
1999 VULCAN 800 CLASSIC (VN800-B4) - Chassis Electrical Equipment
1999 VULCAN NOMAD (VN1500-G1) - Chassis Electrical Equipment
1999 VULCAN NOMAD (VN1500-G1A) - Chassis Electrical Equipment
2000 NINJA 250R (EX250-F14) - Chassis Electrical Equipment
2000 NINJA 500 (EX500-D7) - Chassis Electrical Equipment
2000 NINJA ZX-11 (ZX1100-D8) - Chassis Electrical Equipment
2000 NINJA ZX-12R (ZX1200-A1) - Chassis Electrical Equipment
2000 NINJA ZX-6 (ZX600-E8) - Chassis Electrical Equipment
2000 VULCAN 1500 CLASSIC (VN1500-E3) - Chassis Electrical Equipment
2000 VULCAN 500 LTD (EN500-C5) - Chassis Electrical Equipment
2000 VULCAN 800 (VN800-A6) - Chassis Electrical Equipment
2000 VULCAN 800 CLASSIC (VN800-B5) - Chassis Electrical Equipment
2000 VULCAN NOMAD (VN1500-G2A) - Chassis Electrical Equipment
2001 NINJA 250R (EX250-F15) - Chassis Electrical Equipment
2001 NINJA 500 (EX500-D8) - Chassis Electrical Equipment
2001 NINJA ZX-11 (ZX1100-D9) - Chassis Electrical Equipment
2001 NINJA ZX-12R (ZX1200-A2) - Chassis Electrical Equipment
2001 NINJA ZX-6 (ZX600-E9) - Chassis Electrical Equipment
2001 VULCAN 1500 CLASSIC (VN1500-E4) - Chassis Electrical Equipment
2001 VULCAN 500 LTD (EN500-C6) - Chassis Electrical Equipment
2001 VULCAN 800 (VN800-A7) - Chassis Electrical Equipment
2001 VULCAN 800 CLASSIC (VN800-B6) - Chassis Electrical Equipment
2001 VULCAN NOMAD (VN1500-G3) - Chassis Electrical Equipment
2002 NINJA 250R (EX250-F16) - Chassis Electrical Equipment
2002 NINJA 500 (EX500-D9) - Chassis Electrical Equipment
2002 VULCAN 1500 CLASSIC (VN1500-E5) - Chassis Electrical Equipment
2002 VULCAN 500 LTD (EN500-C7) - Chassis Electrical Equipment
2002 VULCAN 800 (VN800-A8) - Chassis Electrical Equipment
2002 VULCAN 800 CLASSIC (VN800-B7) - Chassis Electrical Equipment

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #12 of 14 Unread 11-28-2019, 09:48 PM Thread Starter
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hey thanks yorkie for all the info. I didn't use the 9v I actually used my power probe it was just easier for me and it definitely seems like I need a fuse box. if I remember correctly I wasn't getting any clicking on the starter circuit/ headlight on relay/diode but im going to double check tomorrow when I get home from work.
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post #13 of 14 Unread 11-28-2019, 09:51 PM Thread Starter
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im sorry it was the headlight relay and trip diode. there was no clicking whatsoever
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post #14 of 14 Unread 11-29-2019, 03:30 AM
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These fuse boxes are easy to open up, only 4 small Phillips screws, and a little jiggling.

If you're not getting the relay to trip, and you're definitely feeding in 12 volts on the right wire, then chances are the diode has blown.
If you know how to use a soldering iron there easy enough to replace, but getting a replacement diode the same might be hard, unless you have an old fuse box laying around.
In the fuse box, there are normally (except in the uk) 2 relays (same type) and 6 diodes (all the same) which would give you a few spares, so when you change the fuse box don't throw the old one away, just label it and keep for spare parts.



Keep us informed on your progress.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 11-29-2019 at 03:34 AM.
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