Er6f - electrical issue

[fatjames]

As per my previous post, there is a problem with my headlight. I turns off when I hit a bump, but will turn straight back on when I hit the starter. I've had a look for a relay (part number - CHKM2006676) but it's moi expensive. Can it be replaced with a cheapo? If so, can anyone help with a link? Last time I bought a replay it was about 50p!

It's an er6f 2012

Thanks guys

[WD Forte]

Dont know the bike just guessing here ok?
(far too new for the likes of me)

But looking at the fiche it appears to be a pretty standard type
CHKM2006676 is 27002 in the pic RELAY-ASSY,SIGNAL LAMP £26.84
If its standard 4 pin type you could probably patch in a cheaper one
( guessing Ok? dont have wiring diagram to refer to)

BUT !

Before I started shelling out on relays and stuff, I'd open. inspect and clean all related connectors as it may well be just a bad or dirty connection causing the relay to drop out.

I'd also open the relay and inspect the contacts to see if there's evidence of arcing or oxidisation on the contacts or the coils been getting hot.
Hate to buy stuff when I dont need to

https://www.kawasakioriginalparts.com/kawasaki_motorcycle_parts/parts_images/MC/99912-1764/F2760.gif
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[fatjames]

Good shout mate. I'll do that and report back.

[fatjames]

To give an update. The relays connectors looked fine and when I pulled it apart the electronics were in a block resin so no repairs could be done. I've replaced the relay and guess what...problem is still there.
The lights come on when I start the bike, hit a bump and they go off. Hit the starter again and they come back on.

What shall I check next?

The choices I see are to take the tank off and follow the wires and check them or is this something to do with the switch gear?

[WD Forte]

Sounds like a dodgy connection or bad earth getting disturbed
when you hit a bump
Possible dry joint on switch gear maybe?

I dont know the bike but I reckon I'd have to gain access to as much of the wiring connectors as poss, (this may well involve removing the tank and panels)
then start testing and wiggling/tapping stuff to try and replicate and localise the fault.
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[fatjames]

I've had another look over the wiring diagram and realised I've been very stupid. The relay that I replaced was for the the fucking indicators! The headlight relay is in a sealed relay box!! I just hope I can find a lose connection.

[Vincent]

I had a similar problem once and it took forever to get right. What was happening was that the fillament in the bulb was broke but any surge of electricity and it would weld itself together and work - until I hit a bump when it would go off again...and so it went on. If not too expensive, and you havn't already, it may be worth trying a new bulb.
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[fatjames]

I have some bulbs, no harm in trying. Thanks mate.

[fatjames]

Right then BCF, lets stop me having to use a mechanic! The relay for he headlight is a sealed unit with 3 relays in, so I swapped it and checked as much of the wiring as i can. After the relays the wires just join the loom. It all looks good and still doesn't work. It's difficult to replicate as when I hit the starter it always comes back on. I'm going to try changing the bulbs later and will report back.
What I can't work out from the wiring diagram is which wire sends the on/off signal to the relay? That must be where my problem is. (Unless its the bulb, of course)

[Aff]

Can you post the diagram?

Im assuming you've had the tank off and checked all the wiring around the headstock for chafing
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[stinkwheel]

Kawasaki will often use more than one relay in a circuit. They sometimes use a microrelay inside a control box to operate a bigger relay elsewhere.

What you have sounds very much like the sort of behaviour I'd expect from a broken latching relay.
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[fatjames]

[fatjames]

Maybe the fuse is being a spaz?

[Hugh Farking Cant]

[fatjames]

I've copied the wiring diagram - https://i.imgur.com/sTRpd6H.jpg

[WD Forte]

Just had quick shufty and cant read the diagram that well but
seeing all those relays I'm wondering if its one of those bikes
where the starter momentarily disables the headlights when the button is pressed?
Seen it other/older bikes, mostly US spec ones and they have been known to play up

as you say restarting ( ie using the starter button)
gets the lights to come on again, I'd consider that as possibility
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[WD Forte]

Just had another squint at it
There's a block of 5 relays at the bottom centre
The right hand one obviously powers the starter solenoid and theres
a feed from that to the headlight relay coil.
( second one in )
This looks to me like the headlight relay is an NC type whose contacts gets momentarily opened when the starter is is use.

I'll go back to my previous comments on checking the contacts on this relay for arcing and oxidisation.
The relays must be removeable and replacable, thats the whole point of using them.

EDIT:
Didnt fully pick up on jn the 'sealed' bit at first so
I just did a google image search and Kawasaki do seem to use
sealed multifunction relay boxes
Sod that, I'd crack that little fecker open if I thought the problem was inside.
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[Aff]

As stinkwheel said, there is a latching relay (No 2) for the lights which is triggered by the starter circuit relay (no 5 the one that triggers the main Starter Relay)

So most likely the No2 relay is dying, or becoming unlatched because of loosing ground. I can see one of those horrible Earthing blocks, so its probably worth checking that for corrosion.
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[WD Forte]

being a cheap bastard as well as tinkerer
I hate to buy anything I cant fix myself
so what I'd do is put a link between the grey and the blue/yellow wires
on the sealed multi way relay box to jump the relay.
Ride up and down a cobbled street and see if the symptoms go away

This will give a permanent supply to the lights when the ignition
is on and you'd obviously lose the headlight cut out
function when cranking.

If it proves the theory, you can make good and replace the relay
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[Vincent]

You could do with a kind ER6f owner to swap a few parts around with
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[fatjames]

But the new relay is doing the same thing. It can't be the relay. It's either the wiring loom or maybe the switch gear?

[Aff]

How have you replaced that relay? I thought you said it was all potted up?
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[fatjames]

The relay looked fine. I replaced it anyway and the symptoms are the same.

[Vincent]

[fatjames]