How-to jump/ bypass relay - Kawasaki Forum ::
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post #1 of 5 Old 03-23-2017, 08:59 PM Thread Starter
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How-to jump/ bypass relay

How do you jump or bypass the headlight relay in junction box. I need to see if that is causing my headlights not to work
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post #2 of 5 Old 03-24-2017, 02:26 PM
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I've done this when my stator wiring etc. started buggering up years ago, I even still have the bit of wiring I made up in my tool box!

Can't remember which junctions to bypass/jump with the wire but if you look into the sticky thread started by zixxer12r, somewhere in there is a picture and details of which part of the junction box to do this with.

It relates to the white wire that leads from the stator wiring and travels up between the frame and tank, it leads to the junction box - this wire seems to burn out when the stator wiring connector goes as it overloads (I believe) and cooks! This wire feeds the front light relays from the junction box (I think).

Or Ninjayorkie may chime in with details!!
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post #3 of 5 Old 03-24-2017, 02:30 PM
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Just rechecked that sticky thread, on the first page he describes how to deal with the stator wiring and has pics of the junction box with what to replace regarding the actual relay for the headlights - I've also done this myself on a couple of occasions, and this may need to be done in your case too!

It's a handy thread and worth reading through.

Hope this all helps.
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post #4 of 5 Old 03-24-2017, 02:33 PM
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Just found the write up on the jumper wire for the junction box...

Try this simple test to be sure it is that small relay, turn ignition on, take a piece of wire and jump the red with a white stripe wire with the blue with a yellow stripe wire on the j-box (under the ashtray), your head lights should come on, if they do remove the jumper, if they turn back off then the small relay in the j-box is cooked, if they don't turn on at all then something is wrong somewhere else (fuses, connectors, relays).

As directly quoted from zixxer12r's write up.
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post #5 of 5 Old 03-24-2017, 02:52 PM
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I know this is a zx9 fuse box but its the same as a zx12 one. You can test a fuse box this way. :: View topic - Fuse/Junction box testing

Or this is how I wired up my zx9 for auto headlights as uk bike are not the same as US ones. It may be of some help. :: View topic - Auto ON headlights

This thread may also be of help. :: View topic - Battery, Regulator, J/box headlight relay & plug checkin

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