zx9r headlight issues

[Dazza1988]

G'day all
just having some issues with my healights on my 2000 zx9r there not turning on at all
now ive check relays fuses basic stuff now ive changed out the junction box under the seat with another bike and my junction box works in his bike but his doesnt work in mine. i cut the top off the relay inside of the junction box and i push the contacts together and headlights are on and stay on till i turn the key off like they should. ive checked that the power is getting from the ignition relay to the headlight relay in the junction box and its fine now as far as i can tell it grounds out through the alternator till is runningand it seems to be getting this ground this is all the pull in winding side of the relay because the switch side is working fine. im just wondering if anyones had this problem or heard of it cause im stumped and cant think of anything
Cheers
Darren

[Andy2613]

Hi Darren I know how you feel It toke me 2 years & 2 bike shops to try to fix it, each shop fixed it for a while but i would always end up with no head lights but the parker would work, They changed both high & low relays & the juction box & rekoned they checked the wireing (cost me a furtune )After i got back from Pi last year where it stopped working on the 2nd day of the trip i rechecked the releys & started going over every wire & connection i could find & i found a brown wire coming from the white fuse box with 2x 20 amp yellow fuses connecting to a white wirehad a shit connection, so i cut out the connecter & replaced it & it's been spot on ever since. Sounds confussing so PM me your email & i'll attact a photo i can't get a photo to upload on this post for some reason

[Dazza1988]

so after a lot of searching i finally found out why my head lights didnt work. beacause my rectifier died it caused the stator to heat up causing one phase on the stator to cook and in turn cook one of the phase wires up to the relay box. now beacause the stator is excited using the headlight relay it couldnt ground the relay through the stator and turn the head lights on
so for anyone else whos had charging issues and has lost there headlights this would most likley be the cause
Cheers
Darren