Headlight Relay

hey the headlight on my bike isn't working. if i jump the relay the headlight works, so i've determined that the relay needs to be replaced. they're expensive new, like $100, so i bought one off of ebay. of course the guy claims it works, and of course it doesn't, so i get him to send me another one, still no luck. has any one ever taken one of these apart and rebuilt them?

Have you tried thoroughly cleaning the connectors? It is possible there is just a layer of oxidation preventing good contact.

From what little I have read rebuilding a relay might be possible, but sometimes when they fail they are damaged and things melt/fuse together. The best case scenario is oxidation preventing contact from being made. The relay might need to be cut open as well. I have never tried to open one of mine.

i've opened two out of the three relays (the original and one of the replacements) and thoroughly cleaned them and especially the contacts, neither one has any noticeable differences from the other or noticeable solder joint failure (albeit, i'm no expert on any of this).
this may sound like a foolish question, but should the contacts be in contact, there is a small gap between them, does the copper coil act like a magnet when it gets the right amount of voltage, causing the contacts to connect and power the headlight?? i don't really know how it works

Check the ground for the relay. Sounds like it isn't getting enough current flow to close the contacts.

Cant you just by pass the relay and run a 12volts to your headlight switch (left control)?The reason why im asking is because I'm wiring up my bike and I'm gonna be using a different controls. My wiring harness also didn't came with that headlight relay.

Remember the reason for the relay is to give the power system a chance to get started before the headlight turns on. Sure you can jump it. perhaps, its time to check all the wiring, to see if all the power is where its suppose to be. Perhaps the alternator has failed?
good luck
Tobie