Headlight Relay Wiring For 2012 Ninja 250

DaveTheWelder · May 27th, 2023, 05:08 PM

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. 😆

DannoXYZ · May 27th, 2023, 08:48 PM

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.

DaveTheWelder · May 28th, 2023, 06:51 AM

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.

DannoXYZ · May 28th, 2023, 11:27 AM

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.

May 27th, 2023, 05:08 PM	#1
DaveTheWelder ninjette.org newbie Name: David Location: Oklahoma Join Date: May 2023 Motorcycle(s): 2012 Ninja 250 Posts: 8	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. 😆

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
New blinkers, did all the wiring but confused with load independent relay flasher	Donut	2008 - 2012 Ninja 250R Tech Talk	4	May 11th, 2014 04:58 PM
[webbikeworld.com] - Dual Horn Relay Wiring Harness Installation Redux	Ninjette Newsbot	Motorcycling News	0	July 13th, 2013 07:40 PM
08 Ninja 250 : Other Issues due to Headlight Circuit Relay	abhijitz	2008 - 2012 Ninja 250R Tech Talk	1	February 26th, 2013 05:41 PM
2008 250 Headlight Relay	brittany88	2008 - 2012 Ninja 250R Tech Talk	2	August 5th, 2012 08:12 PM

May 27th, 2023, 08:48 PM	#2
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	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.

May 28th, 2023, 06:51 AM	#3
DaveTheWelder ninjette.org newbie Name: David Location: Oklahoma Join Date: May 2023 Motorcycle(s): 2012 Ninja 250 Posts: 8	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.

May 28th, 2023, 11:27 AM	#4
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. 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.