Electrical issue

Today I had an electrical issue pop up on my indian summer bonus ride.

At about mile 80 I slowed to take a hard left turn, downshift to 1st, look press and roll and after I straightned out shifted to 2nd. As I let out the clutch the bike died like it had been turned off. Main (20A) fuse was blown.

Pop in a replacement fuse and much to my surprise everything was fine, for the next 40 miles. Start to let out clutch at stop sign and dead again. Pop in new fuse and head for AutoZone (was my last spare 20A). Four miles late come out of AutoZone and bike is dead. Pop in one of my new fuses and off I go.

Hit a stop sign, make left turn, shift into 2nd and as I let out clutch dead again.

I figured clutch cable movement was moving a wire that was worn. Give clutch cable several tugs back and forth, now blows fuse as soon as key is turned on. Wiggled all the wires around where they pass through headlight bucket, using a jumper now instead of fuses because I am running low. Fuse holder gets hot enough to partially melt (aftermarket mini blade in line waterproof holder).

Reach up under tank and start wiggling wire bundles. A relay drops down (photos below). Now everything is fine. Ride bike last 20 miles home.

At home pull headlight and tank. Inspect everything I can get my hands on. Everything in the headlight bucket is good. Everything under tank looks good. Trace length of clutch cable and all electrical looks just fine.

Now I'm wondering if this relay could be the problem (it was tucked up close to clutch cable). Thing is, I can't figure out what the relay does besides give a reassuring click when the key and run switch are turned on. Everything seems to work the same whether the relay is plugged in or not.

Anyone know what this relay is?

 

dont know if its the same for your maxim?? but i had a relay on my 82 vf750c magna that looked just like that and what it was for was the turn signals, when i turned the key on to start the bike it used to click about 3-4 times.

like i said dont know if it has anything to do with your relay but mine was identical to that one.

 

'Taint the flasher rleay. They work just fine without it. I didn't ride however so I guess It could have something to do with the auto canceller.

 

If that relay is from under the center of the frame, to the rear, close to where the tank gets bolted down ...

It's the infamous "Safety Relay"

Wired to the Clutch Switch, Neutral Switch and Side Stand Switch ... it's function is to Prevent the Bike from Starting unless the Safety Circuit Switches are correctly opened or closed as required.

In Neutral the bike should start and run.
With the Side Stand UP ... Start, Run and be placed in gear.
IN Gear ... Start with the Clutch Lever Pulled.

That Relay is Unique. Not the same configuration as the other Relay's which are considered "Generic." (Signal current and switch poles opposite from a standard relay.)

Substituting a Generic Relay for a Safety Relay will cause an unsafe condition to occur ... such that the Starter will ENGAGE > and the Bike will START -- when > IN GEAR > CLUTCH LEVER **RELEASED** > START BUTTON PRESSED!

 

Safety relay is what I thought 1st. The relay that acts like I'd expect from the safety relay is where you described, and it clicks if I pull in the clutch.

The relay I'm wondering about doesn't seem to have any mount and hangs from the wiring harness at about the center of the tank (pretty much above the rear of the head). Actually, if I recall correctly, the pigtail for the relay comes out of the harness about the same place as the primaries for the coils.

Seems to be a generic relay as there are only 4 wires going to it. It has a blue tab that allows the wire connector to only go on one way.

 

I think that's the Headlight Relay ...

What happens if you unplug it?

 

Ok, everything on the bike works exactly the same whether the relay is in or not.

I've reached the conclusion that it is the sidestand relay. The sidestand switch is either broken or disabled (you can run in gear with sidestand down). The sidestand relay works by grounding the TCI control current so having the relay out would disable the sidestand cut-out. Also, wire colors seem to mach the Yamaha manual.

Only thing is, the Yamaha manual shows the Starting-circuit cut-off relay in this position. Since all the starting stuff works correctly with the relay removed (won't start in gear unless clutch is pulled) I think the Yamaha folks must have switched their photos.

Anyhow if/when the problem recurs I can see if pulling this relay makes things right.