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Old May 27th, 2023, 05:08 PM   #1
DaveTheWelder
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Name: David
Location: Oklahoma
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Motorcycle(s): 2012 Ninja 250

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Headlight Relay Wiring For 2012 Ninja 250

I just acquired a Ninja with melted wires where the headlight relay used to be. I've searched but can't find just that set of wires, only entire wiring harnesses. If you got one thats already cut up but still has that wiring I need it. I can cashapp, PayPal whatever. In the meantime, I'm just gonna wire in a switch between the fuse block and the headlight switch. 😆
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Old May 27th, 2023, 08:48 PM   #2
DannoXYZ
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Here's wiring for headlight relay. Which segments do you need?



I probably have it in this bag of non-essentials from my race-bike. All wire terminals were extracted cleanly from connectors with nothing cut. So you should be able to re-insert into your harness without any issues.



Melted wiring is just symptom of wiring problem. You should track down exact fault that caused wiring to melt, such as short somewhere. Perhaps PO tried to force headlight to turn ON with key ON because they couldn't believe that headlights only turned on when engine was running.
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Old May 28th, 2023, 06:51 AM   #3
DaveTheWelder
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I've been through the wiring and didn't find any shorted. The only thing I find weird is that the red wire is only supplying 6-7 volts DC while it's running. I still need to do some tracing on that one.

The section I need is the 4 wires going into the headlight relay, the connector and the relay itself. Everything else is good.
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Old May 28th, 2023, 11:27 AM   #4
DannoXYZ
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MOTY - 2018, MOTM - Nov '17
trigger red wire to headlight comes from one yellow wire from
stator and is rectified (single phase) by diode.

Do standard stator tests:

1. ohms between stator phases 1-2, 2-3, 3-1
2. ohms between stator wires and ground
3. measure AC output of each phase at idle and 3000rpms

You may have a fried stator from factory shunt-circuit RR driving it at 100% fulltime. If so, best to upgrade to series-circuit RR for greatly reduced operating temps of both stator & RR. Frees up HP and MPG too!

I'll look for headlight relay socket & parts his weekend.
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