Just started today but everytime I flick the low beam on (pretty much the start of every ride) the engine just dies and then is a pig to start again.

I installed the low beam relay 2 weeks ago and it's been fine til now. But riding over to my gf's with only the sidelights on the bike felt crisper, faster acceleration and more responsive.

Short somewhere?

Could be a short or it could be the stator on the way out or the reg/rec packed up.

Stator is a recently fitted GSXR item, reg/rec tested fine not long ago too.

Shall have to get out my multimeter next week.

Right just had 5 minutes to look at the wiring diagram and stuff, and I'm completely stuck as to where to look after testing the charging system again and checking my low beam relay wiring.

If it's not there is there any way of isolating a certain part of the wiring where the fault could be?

I'm still useless when it comes to fault finding......

Does low beam still function? Your post describing the installation of the low beam relay suggests that you soldered the wires to the relay. If this is the case you may have damaged the relay with the heat required during the soldering process, the relay would have high percentage of plastic in its construction and thus be susceptible to heat.

Alternatively, one of the solder connects to the relay may have failed and the loose wire is causing a short, the spade terminals on the relays are quite often plated to stop corrosion and thus solder does not adhere well to the terminal unless the plating is removed.

Yeah I did solder the connections on the relay and I remember it being a bugger to stick.

Haven't checked the headlights since the problem arose, that'll be my first port of call tonight.

I'd buy another relay and a packet of spades. Crimp and solder the spades to the wires, and plug them into the relay. If as you seem to suggest it took ages to solder to the terminals, there's a strong chance you've knackered the relay, which as Magg suggests means a while lot of nastiness may be going on inside it when it is energised.

Aye seems to be the case.

Ordered another relay and some spade terminals earlier whilst at work. Just about to pop into the garage to have a gander.

New relay arrived this morning, thank you very much fit new post lady

So got it fitted with spade connectors and it works perfect. Relay was to fault, 87 was wiggly because the plastic had melted.

Offending item



Wiring in spade connectors and plugging in



All taped up and held in place with clutch cable






Going to test a theory later too. When I rode the bike the other day with just the sidelights on it felt much more responsive and quicker, could this be the low beams drawing so much power from the battery the plugs aren't getting a hard enough spark?

I suspect that the problem was a faulty relay that caused a short to the electrical supply whenever you selected low beam, unless you have another electrical issue that is drawing excessive current.

Did you happen to try high beam when you first had the poor engine running when on low beam? If so, did the bike run ok when high beam was selected?