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Discussion ZXR250 Headlights H4R

Discussion in 'Kawasaki 250cc In-line 4's' started by DanoHosko, Apr 27, 2020.

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  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    ZXR's have a 6th wire on the reg/rec that is either a voltage sense wire or is part of the headlight circuit. It's cutting the headlight because the battery isn't being charged sufficiently. You should do a complete check of your charging system.
     
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    Linkin, May 7, 2020
    #21
  2. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Man you're a wealth of knowledge i swear!

    That would make sense since I had to replace the battery

    I do have the smaller 35W bulbs ready to fit rather than the 55W so that may help too

    Thanks bud again :bowdown:
     
    DanoHosko, May 7, 2020
    #22
  3. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    WHOAH, how good is this place, gives concise consistent results and answers to questions better than google and information which higher quality that wikipedia
     
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    ruckusman, May 7, 2020
    #23
  4. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Edited

    Think i had a loose connector, seems ok now, will see what happens when i go for a ride, passed RWC today
     
    Last edited: May 7, 2020
    DanoHosko, May 7, 2020
    #24
  5. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Sorry to drum up an old issue post

    So finally got round to getting a new rectifier, and have found my old one only has 5 wires connected, looks like the Brown is missing

    According to the wiring schematics the brown does headlights and other bits, white looks like it charges the battery.

    My headlights work for periods at a time when i ride
    Im wondering if the headlights are somehow wired to the charging side of the rectifier?
    Presuming that the charging side turns off when the battery is fully charged?
     
    DanoHosko, Jul 6, 2020
    #25
  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    A 5 wire reg/rect is internally excited, so doesn't need the sense wire
     
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    my67xr, Jul 6, 2020
    #26
  7. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Hmm mine actually has 7 wires with two cut off hahaha
    The Brown, which is missing, looking at the drawing this should supply various things (horn, headlights etc)
    I cant see how anything is working without that brown wire connected unless its been bodged somewhere else...?
     
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    DanoHosko, Jul 6, 2020
    #27
  8. risky

    risky risky

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    try an led bulb as they draw a lower current.
     
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    risky, Jul 6, 2020
    #28
  9. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Personally I'm more convinced its a wiring issue than a current draw issue


    As per picture, its blurry, but does this mean when Ignition is On, the White and Brown are connected?
    Ignition.PNG


    Reg/Rec:
    3x Yellow stator, BK/Y ground
    White goes to Main Fuse and Battery
    Brown feeds the headlights etc

    RegRec.PNG

    Is White the voltage sense??
     
    DanoHosko, Jul 10, 2020
    #29
  10. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ok i think the Brown is the sense wire
    And as people have said, the Reg/Rec installed without the sense wire probably doesn't need it but is still turning off the power to headlights etc, which are fed through the Ignition barrel.

    Long story short, I'll put on the new Reg/Rec and hope that works (i have found the brown wire cut and taped off)
     
    DanoHosko, Jul 10, 2020
    #30
  11. DannoXYZ

    DannoXYZ Well-Known Member

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    Do you have schematic of headlight relay?
    Is it in fuse/junction box?
     
    DannoXYZ, Jul 23, 2020
    #31
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