Author Topic: headlight relay  (Read 625 times)

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Offline Rico

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headlight relay
« on: July 22, 2018, 02:02:21 am »
Where is the headlight relay located on a 2002 Concours?

Offline oldsmoboat

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Re: headlight relay
« Reply #1 on: July 22, 2018, 02:17:26 am »
J Box under the seat.  The connections in the boxes are known to get corroded.

Offline Rico

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Re: headlight relay
« Reply #2 on: July 22, 2018, 02:28:32 am »
Thanks,must have passed right over it. I'll look into into it in the AM.

Offline oldsmoboat

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Re: headlight relay
« Reply #3 on: July 22, 2018, 03:03:23 am »

Offline Rico

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Re: headlight relay
« Reply #4 on: July 22, 2018, 03:30:11 am »
Yeah,I came across that also. My headlight works fine until the bike warms up and then lights out (headlight only). When I was dropping my truck off for a brake job this afternoon I told my mechanic about it and the first thing he said was "relay". I have a new one,just have to find the old one. Guess I'll do some diggin'.

Offline Bud

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Re: headlight relay
« Reply #5 on: July 22, 2018, 08:14:58 am »
I believe the relay you're looking for is inside the junction box.  It's a common problem to have bad solder joints on the circuit board where the relays are attached to the board.  Get a known good J box or send yours off to Larry Buck for a rebuild.  HTH
2005 Kawasaki Concours
2001 Kawasaki Concours
1982 Suzuki GS1100GK
1983 Honda GL650I SilverWing

Offline connieklr

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Re: headlight relay
« Reply #6 on: July 22, 2018, 10:25:41 am »
Relay locations:





Most common failure:


« Last Edit: July 22, 2018, 10:31:44 am by connieklr »
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Offline Rico

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Re: headlight relay
« Reply #7 on: July 22, 2018, 01:15:15 pm »
Thanks. Found a reman with lifetime warranty for 75.00 and 30.00 trade in so I'll give that a shot. Let ya know the outcome.

Offline oldsmoboat

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Re: headlight relay
« Reply #8 on: July 22, 2018, 02:00:24 pm »
connieklr, thanks for the pics.

Offline Rico

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Re: headlight relay
« Reply #9 on: July 31, 2018, 10:10:19 am »
Nailed it. Found a guy in Texas that rebuilds 'em,seals 'em, diodes and all. For 75.00 and if you return your non fried one intact fuses,puller and all he refunds you 30. Better than a few hundred bucks at the shop.PHXBCD

Online MAN OF BLUES

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Re: headlight relay
« Reply #10 on: July 31, 2018, 07:10:40 pm »
Nailed it. Found a guy in Texas that rebuilds 'em,seals 'em, diodes and all. For 75.00 and if you return your non fried one intact fuses,puller and all he refunds you 30. Better than a few hundred bucks at the shop.PHXBCD

might consider one of our trusted, longtime members, who is also an Industry Member, for this service... I think he charges $70 with your swap...

https://www.bucksporttouring.com/

ride safe

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