Post Master General
Join Date: Apr 2012
Location: Bowling Green, VA
I Ride: '09 ZX6R
My guess is that the relay isn't actually turning off the ballast for the HID, when you think you are turning it off. The ballast is probably trying to provide power to the bulb, and is possibly arcing, or is being overpowered so the coil isn't being held in the position it is meant to be in.
The only way the relay could vibrate, is if the coil is being excited by pulsing power. Part of the issue is going to be whether the switch is opening the positive side, or the ground side of the circuit going to the coil of the relay. If it's opening the return, there is a chance that the wiring between the relay and the switch is already grounded to some degree. You could have a 'leaky' open. Inspect the wiring between the switch and the relay to make sure nothing is melted, chaffed, burnt, etc. Bare metal touching the frame is enough to cause odd stuff to happen. Take a close look at wherever the splices were made to install the controls for the HID, and LED halos to make sure the wiring isn't exposed at any of those points.
It could be a relatively simple fix, if you can put a diode in line to limit the direction current can flow to the relay coil. provided everything else is in good shape.
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