HELP - ZX636 05 Headlight Issue

all_mee · Post by **all_mee** » Sun May 13, 2012 11:07 pm

Hi Guys,

I have a strange problem with my 05 zx636. If I give any gear a good rip past ~12,000rpm, my headlight turns itself off. This was pretty scary the other day when I was driving at high speeds at night. I've now noticed that if this happens, I can reactivate my headlights by turning on my indicator, and then turning it off again. As soon as I do that, the headlight turns itself back on.

Strange problem - anyone heard of this? And how do I fix it??

6maniac · Post by **6maniac** » Sun May 13, 2012 11:28 pm

Keep rpm to 11999 or less ....

Saki · Post by **Saki** » Wed May 16, 2012 6:53 pm

I assume you've modded your bike some how ? Or is it stock ?

all_mee · Post by **all_mee** » Thu May 17, 2012 8:48 am

Bike is completely stock besides a slip on exhaust that was professionally installed years ago. Electronics have never been tampered with. I take it this isn't a common fault

tim · Post by **tim** » Thu May 17, 2012 8:56 am

Not common, might make sense to an auto electrician. If you can post a link to the wiring schematic of your bikes electrical system we might be able to give you a hand...

First thing I would do would be to pull apart the light/blinker switch block on the handlebar and spray everything with contact cleaner, turn switches on and off fast over and over, look for corrosion/breaks etc.

tim · Post by **tim** » Thu May 17, 2012 9:05 am

Another thing to do is see if you can duplicate it just sitting there revving it... If it still happens will helpyou diagnose it

all_mee · Post by **all_mee** » Thu May 17, 2012 11:53 pm

tim wrote:Not common, might make sense to an auto electrician. If you can post a link to the wiring schematic of your bikes electrical system we might be able to give you a hand...

First thing I would do would be to pull apart the light/blinker switch block on the handlebar and spray everything with contact cleaner, turn switches on and off fast over and over, look for corrosion/breaks etc.

Thanks Tim. Will start revving in the garage to see if the problem persists.

Do u have any idea where to start when pulling apart the light/blinker switch box?

tim · Post by **tim** » Fri May 18, 2012 1:54 am

The bolt that holds it together

Blurr · Post by **Blurr** » Fri May 18, 2012 1:58 am

6maniac wrote:Keep rpm to 11999 or less ....

12K on a 6r is just above idle

Post by **Wattie** » Fri May 18, 2012 6:45 am

Blurr wrote:
6maniac wrote:Keep rpm to 11999 or less ....

12K on a 6r is just above idle

Dont they idle at 7k?

loubre · Post by **loubre** » Tue May 22, 2012 7:49 pm

Wattie wrote:
Blurr wrote:
6maniac wrote:Keep rpm to 11999 or less ....

12K on a 6r is just above idle
Dont they idle at 7k?

Nah That's just where the fun starts

StuMiller · Post by **StuMiller** » Tue May 22, 2012 8:40 pm

Try doing a wheelie and see if that helps.

Then maybe a burnout at 13k rpm...I think that will do the trick!

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