Relay assembly vibrates when headlights off - ZX6R Forum
 
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post #1 of 11 Old 05-09-2017, 09:56 AM Thread Starter
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Relay assembly vibrates when headlights off

the relay assembly on the right side of the bike (the one that slips into that rubber holder) has started to vibrate when my headlights are shut off. Is this an issue??

The headlights are HID replacements that have been wired to a switch. When they are on, there is no vibration, when they are off, the relay assembly vibrates, HARD. To the point where it's slightly audible over the exhaust even with cowling on. I haven't noticed any other electrical issues occurring because of this. I opened up the relay assembly to see if there was any water intrusion or dust causing a ground and I did notice a pink spot on a part of the card, but inside was clean and no sign of damage.

Should I be worried about this? Could it cause any sort of major (and by that I mean expensive) issues for me in the future? Please help! Every shop I called has no
Idea
Thanks guys!
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post #2 of 11 Old 05-09-2017, 10:12 AM Thread Starter
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Forgot to mention it's an 07. Thanks again all!
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post #3 of 11 Old 05-09-2017, 12:08 PM
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So u have a switch that turns the relay on and off??
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post #4 of 11 Old 05-09-2017, 12:40 PM
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If you don't mind.. Could you please post of picture of the assembly.

I noticed a noise from a module. Makes me wonder if it is the same thing.
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post #5 of 11 Old 05-15-2017, 02:36 PM Thread Starter
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Hey guys! Sorry it took so long to respond!

Here's the low down on my lighting configuration. I have LED Halos tied into the line that controls the normal singular running light. My HID headlights are directly tied into start (as per normal) however they have a three way switch (On-Off-On) so that I can run with headlights off and just the halos on. I posted a picture of the relay below.

Here's a link for a video that shows the noise.


as a secondary issue now my gauge cluster won't show info now. It is backlit, all the lights for neutral, turn signals and high beam all work, but the tach doesn't read, and it won't display mph, mileage, etc.....feels like cascading electrical issues.... -_- sighhhh time to open the manual I suppose.
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post #6 of 11 Old 05-15-2017, 02:48 PM
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Sounds just like mine.. I don't have any lights. Race fairings.
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post #7 of 11 Old 05-15-2017, 04:03 PM Thread Starter
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Weiiiirdd.. How long has it been going on for? Notice any real performance issues or cascading affects from it while riding?
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post #8 of 11 Old 05-15-2017, 10:36 PM
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That relay shouldnt be rattling like that. Open that box up. I havent seen what the inside looks like but if its individual relays then replace it with another one.
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post #9 of 11 Old 05-16-2017, 08:15 AM Thread Starter
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I'll open it up and post the pictures in the next couple days. I looked in it, and I did notice a pink spot on the card (scorch mark??) but I don't know what it looks like normally so with nothing to reference I wasn't sure. Looking like I need to replace then you think?


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post #10 of 11 Old 05-16-2017, 09:19 AM
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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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post #11 of 11 Old 05-16-2017, 09:25 AM
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Quote:
Originally Posted by RJ2112 View Post
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.
Just odd mine is doing the same thing.
No lights on the bike. Does that module come apart, looked sealed at first glance.

If it wasn't such a pain to get to it I would pull it apart.
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