all EX500 (north american) "D" models (94 on) have the same wiring. the bike is a 06 the stator wire (AC) goes to the junction box and then through a set of diodes to turn it into DC this powers the headlight relay to turn the headlights on,I have a question. I still don't know what year this is. But the drawing I looked at shows the stator wire going to the junction box, normally the lights come on only after the bike is running. Secondly , pushing the start button turns the lights off.
I need to resolve this first.
Yes , almost all Kawasaki are wired this way. I am waiting for a reply from this guy- the headlight relay should not energize with a key on, which is what he said. I suspect several diode failures that, or the headlight relay is fused, which does happen. I have a cheap $5 40 amp relay work around for this problem on the versys, and imagine it would work here.all EX500 (north american) "D" models (94 on) have the same wiring. the bike is a 06 the stator wire (AC) goes to the junction box and then through a set of diodes to turn it into DC this powers the headlight relay to turn the headlights on,
so when the engine is stood there is no power to switch on the headlight.
here goes-I asked to unplug the connector at the start solenoid-key on and tell me if the headlights work-if they do the headlight relay is toast-or you have some screwed up wiring. When you ask why it won't start-I work backwards-since I can't be there, I need to prove circuits. Like the start solenoid cannot turn over by itself unless it is shorted, the same goes for the headlight relay, they don't just come on. Also I wonder if he disconnected the 3 phase plug and regulator plug before trying this.
Junction Box Circuit
I will come back later and post how to test the relay box using diode test, forward and reverse bias.Junction Box Circuit
View attachment 55590
A. Accessory Fuse 10A
B. Fan Fuse 10A
C. Turn Signal Fuse 10A
D. Horn Fuse 10A
E. Ignition Fuse 10A
F. Headlight Fuse 10A
G. Headlight Relay
H. Headlight Diodes
I. Starter Diode
J. Starter Circuit Relay
K. Interlock Diodes
L. Taillight Fuse 10A
One of my favorite aspects about the EX is, it doesn't have a lot of frills like on board computers or fuel pumps.
But then it seems like something always does
It's not supposed to happen.i replaced the fuse in the starter solenoid and now the bike runs i don't understand why you think the headlights coming on with the key isn't supposed to happen.
Check my edited post above.
yeah quite simple there is no headlight relay in the junction box (only the starter relay) and no wire from the alternator is fitted. the light switch is duel fed from both a permanent live feed (for the side lights) and an ignition feed (for the headlight), side light can be on when ignition is off (depending on switch position) headlight on when ignition is on whether the engine is running or not. (depending on switch position) because it is not a legal requirement to have the headlight on while riding,Check my edited post above.
Could you explain the purpose of the headlight relay in regard to the drawing.