Testing a Headlight Relay on ZX7R

[Roy66]

Hello I wonder if I could seek some advice? I have a 1999 Kawasaki ZX7R. I have a problem in that my dipped headlights work normally but when I switch to main-beam, they go off? The passing light / flasher doesn't work either. All other lights (dash, indicators, tail-light, plate light all work. 

I've heard that this problem often relates to the headlight relay. I eventually located it amongst the spaghetti in the nose-cone. These are the tests I carried out:

1. Fuses - all intact

2. Remove the relay and turn on lights without relay. This has no effect. Still have dipped beams but no main beam.

3. Trying the lights when engine is running / not running - no impact.

 

So looking at the relay, it looks quite corroded so I thought I should test it with a multimeter. I'm no auto electrician, but did my best! I set my meter to 2M ohms (as that was the only setting which gave me a reading). One set of pins gave consistently higher readings than the other, and the readings were generally jumping all over the place Any ideas? Do you think the relay is working or is it knackered and needs replacing? Thanks in advance.

[Fiddlesticks]

On my Tiger Explorer I have the same problem the opposite way around (main beam works, dipped headlight doesn't). Current theory is a bad connector, but I've got to take the tank off to find out.

 

[Mississippi Bullfrog]

I assume you've checked the high beam filament by wiring the bulb to a battery.

 

Testing relays....I'd usually cobble together a test circuit to activate the relay. Its the surest way of checking. 

 

But if it's corroded with fluctuating readings then chances are it's toast. They aren't expensive so bung a replacement in. 

[Roy66]

Hello I decided it would just be quicker to get a new relay. It's a DENSO 056700-5260 22amp. Got it for £10 including delivery so will post progress when it arrives. Thanks.