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05' 250X:

Last year my battery died in the middle of the day. I did bump start once that day. I thought a wire had come loose (i have asv levers and by-passed the clutch starter). Some how the led tail light burnt out. Got a new battery everything was fine (except the tail light)
until yesterday. Samething minus the bump start. I checked the voltage: 6.45 @idle up to 14.4 with revs. 12.3 @ rest. I have no voltage at the tail light and some how the headlight runs off 1 volt?

DO I HAVE A BAD RELAY? OR SOMTHING?

i guess I know somthing is wrong

I would look for a pinched or broken wire. LED's by nature do not burn out. If you only have 1 volt at the headlight, the headlight would be very dim, if not lit at all.
1) check your volt meter settings/function.
2) If both systems (i.e. headlight/ taillight) are non functional then check right from the source of power (battery, stator, etc)
3) Can you kick start it?

I may stand corrected but I am of the understanding that the battery's only function is to run the starter. The bike's own power should run the lights, charging system, etc.
later...

I would agree the the Batt is for starting. The bike kicks over and runs well, light is dim at idle and normal when reved up (from what i have read thats normal). Volt meter works fine on all other batts I tested. I thought is was strange the headlight voltage was less but it was coming off the A/C side like the tail light except the headlight is still working fine. A bought a new tail light, but the output leads don't seem to to have any voltage. Tail light works when wired direct and headlight is fine.

I had to replace the CDI unit when my taillight was inop.
The CDI grounds the grey wire to complete the circuit when the bike is running.

The 04 is wired differently but I would check that out.

Ill check that out. CDI sound expensive but ill deal with it. thanks