electrical issue - low beam

[Coxyzxr]

Ok, lets try again.

I'll use these terms;
[pass] - pass switch for HI beam
[headlight on] - headlight switch to switch dash lights ON then headlights ON or OFF
[hi/lo dimmer] when lights are on flick between permanantely HI or permanatenly LO

Right !

Lo beam will not work at all, ALL other electrics work fine on the bike, when I switch lo beam on, it doesn't come on. The dash lights come on fine. the [hi/lo dimmer] doesn't work either.

The switch tests fine.
Now it gets interesting,

If you put HEADLIGHTS ON, put [hi/lo dimmer] onto HI then flash the [pass] light the [hi/lo] dimmer now works but only for high beam, low beam still does not work.

It's almost like the [pass] switch is working as a toggle switch for the [hi/lo dimmer]. If you switch the bike off then back on you have to repeat the above procedure to get the [hi/lo dimmer] to work again.

I've wired the headlights directly to the [headlight on] switch and still they do not come on, BUT when you use the above procedure they will now come on, but only since they are wired to the [headlight on] switchgear directly instead of going through the junction box.

Now I've tried 3 junction boxes, 1 definitely known working
3 seperate relays with 2 definitely known working(as well as swapping them around with each other) but results still exactly the same.

There is a headlight relay in the junction box but since I've tried 3 others as well as seperate hi and lo beam relays which I've swapped out.

WHY is the [pass] switch acting like a toggle switch on the [hi/lo dimmer] and lowbeam (but only when it's wired directly to the [headlight on] switch.
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**WAS FITTED "WRONG WAY ROUND" !** CANT ACCOUNT FOR THE STUPID !

[stinkwheel]

Read this out loud:

"Zxr 750 everything going ok, headlights/lowbeam won't come on with headlight on switch. 'Pass flasher' will work fine and flash full beams. BUT headlight on switch and put beams to the 'high' (from hi/lo) switch they still won't come on even though u can flash the full beam with the pass flasher, u will not here the headlight relays click either. however, put them on high then use the pass flasher they will then come on then the hi/lo switch works with the headlight on switch but only for full beam.you can now also here the lo beam relay click where as u could not before doing this procedure, so this tells me the headlights on switch and the hi/lo toggle is fine there's just some odd stuff going on somewhere.

Then try again because it's giving me a headache. If you've written it in a coherant manner, reading it out loud will sound like someone speaking normally.

Check the fuse anyway. The "pass" button is often not wired through the headlamp fuse on Kawasakis. I have no idea why.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Coxyzxr]

Sorry chap I'm on an ancient mobile phone with a 2inch screen and no javascript support so I'm seeing and using the internet as basic as it gets.

Let's leave it and I'll see if I can get to a computer tomorrow to type up a more intelligable post.

Regardss
____________________
**WAS FITTED "WRONG WAY ROUND" !** CANT ACCOUNT FOR THE STUPID !

[Ichy]

Try cleaning the switch wiring connector blocks. It may well just be a bad earth somewhere.
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[Coxyzxr]

edited for a bit of clarity guys, the problem is complicated so it's hard to word it simply.
____________________
**WAS FITTED "WRONG WAY ROUND" !** CANT ACCOUNT FOR THE STUPID !

[Ichy]

Is the rear light working?

What is a junction box?
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[Coxyzxr]

[stinkwheel]

I'm pretty sure the problem is somewhere between the headlight switch and the headlight relay in the fuse box.

The headlight relay is weird on kawasakis. I have no idea why but they have put a feedback loop on that relay.

If there is no trigger voltage being applied to the relay (from the headlight switch). A voltage in the power out from the relay will feedback and turn it on. Pressing the "pass" button would do just such thing.

That's tricky to explain. I've done you a drawing (colours not correct).

Normally power is supplied to the headlamp relays from that relay in the fuse box via the wire marked "to headlamp relays". To do this power from the headlamp switch triggers the relay.

BUT, See that loop? Even if there is no power coming into the relay from the headlamp switch to trigger it and 12V appears in the feed to the headlight, it'll turn on. Pushing the "pass" button would do this.

TL;DR The headlamp relay in the fuse box isn't powering up for some reason. Most likely a problem with the headlamp switch or the wiring between that and the fuse box.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Coxyzxr]

Stinkwheel, increidbly informative and helpful thank you!

When the wires come out of the headlight on switchgear they go into a block connector that someone has replaced as it just runs 4 black wires to the fuse box instead of oem wiring colour.

Now, tracing this to the fuse box reveals some bodgery that has some male/female crimp connectors outside of the fuse box that seems an attempt to bypass some of it, for some reason. I thnk the problem lies within this bodgery.

Some of the black wires are crimped onto the (headlight on wires) instead of being routed via the fuse box.

I can't seem to work out why it's been done which makes putting it back to 'working' harder.

It may be easier just to buy a new loom.
____________________
**WAS FITTED "WRONG WAY ROUND" !** CANT ACCOUNT FOR THE STUPID !

[stinkwheel]

Down this path lies danger!

There is all sorts of stuff hooked into the wiring in that fusebox. I think the fuelpump is fed by the same wire as the headlamp relay.

I would strongly suggest either replacing with the original wiring or getting a really good wiring diagram of the contents of that box before doing anything more.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.