Looking for a Headlight Relay

Does anyone know where I might be able to buy a used or new Headlight Relay in or near the NY State area? It is a Headlight Relay for a 1982 XJ Maxim 650. Don't have a part #, worn off or a paint mark on it. But the tab at the plug in area is black. I have noticed that the tabs on the relays are color coded.
Problem that I have been having getting one order is with electrical parts ordered from a dealer, you have to pay for it first and if it is the wrong part you have to own it anyways. Have done this once and ended up getting a side stand relay.
I need the Headlight relay, controls the headlight, and high beam and light pannel for directionals and neutral light.
Also I am looking for the plastic cover plate that fits over the battery area. I needs to be Red.

Would appreciate any help or directions on where to find these items.

Marsh

 

Marsh, have you tried to open up the case and clean off the contacts yet? It can be done with a small screw driver and some patience. Might save you some misery and some more money. You might also want to contact our resident Yamaha parts man, Chacal. He might have exactly what you need.
Best of luck.

 

Robert ,
Thanks... No I haven't tried cleaning the contacts. Didn't know you could. I did open it up to see what it was in there and if something broke off, or disconnected. I have only owned one bike, for the past 5 years, and this is it. Brought it in pretty good condition, learned to ride on the XJ and this has been the first problem I have ever had. Other than front brakes which I did. Never was around bikes before this one. Ran into so many problems trying to get the right relay order, and money to. Found this site after searching.
Thanks again, and I will try the guy you mentioned as well.

Marsh

 

Here it is:

Headlight Latching Relays:

hlr1) OEM headlight system HEADLIGHT RELAY. This relay prevents the headlight from coming on while the starter motor is being engaged, thus allowing maximum battery voltage to be used by the starter and the ignition system. However, it is dependant on voltage draw in order to energize and "latch" into the on position, and thus if the engine gets spinning fast enough during the starting process (whether the engine fires or not), enough voltage will be produced by the alternator (which increases its output with RPM's) to eergize this relay, and thus lighting the headlamp. Also, once latched on, the headlight relay remains latched on until the ignition switch is turned fully off.....thus, if you (for example) stall the bike, and hit the starter button, this relay will remain latched and the headlight WILL remain lit during the starting process. Only by turning the key to the off position can you de-energize this relay (and thus turn the headlight off).

Identification: The Headlight Relay is a small square metal "can" relay, and has a small yellow paint "dot" or yellow locking tab, and has the following 4 wires connected to it:

- XJ550 all models and XJ650 all models except Turbo: a solid black wire, a solid white wire, a blue wire with a black tracer stripe, and a red wire with a yellow tracer stripe.

- XJ750 Seca models: a solid black wire, a white wire with a blue tracer stripe, a blue wire with a black tracer stripe, and a red wire with a yellow tracer stripe.

NOTE: original relays were always a square metal can style, although they may have been replaced by an automotive style plastic relay.


HCP429 OEM main HEADLIGHT RELAY. For all XJ550, XJ650 (except Turbo), and XJ750 Seca models.
$ 79.95

HCP429VGU OEM main HEADLIGHT RELAY. For all XJ550, XJ650 (except Turbo), and XJ750 Seca models. Very good used condition, guaranteed to work (but NOT guaranteed to fix your problem!).
$ 19.95

 

Robert. I tried cleaning the point connections inside the Relay. Put back together and it didn't help. I was just dead and wouldn't try to start. But Thanks for the suggestion it was worth the try.

Chacal,
Thanks for writing and letting me know what the Relay is and how and why it works. My headlight relay is not as you discribed to me for the XJ650. I have the manual for the xj650 J, and the VID# on the bike is JYA5N800. With markings on the frame of 5 N8 006017. The Headlight relay on my bike is located under the tank and down near the lock down bolt for the gas tank. It has a black locking tab.. The wires going into the four plug female is the best I can see is (2) red wires both with white tracers and are on the same side above and below each other. The other side top wire in is a solid light blue, and below that is a Black wire with a yellow tracer. I looked in my manual on page 120. It show the location of the relay where mine is, and the diagram wires look to be the same colors, R/y, B/y, L/B going out to the Head light and Meter light, and to high beams.
Wonder if you could tell me if I am reading this all right? And is it the headlight relay that I am dealing with? And do you have this relay that you could sell to me??
Right now, just to start the bike and let the engine run a few times a week, I have the side stand relay, blue locking tab, plugged into the Headlight socket. I don't have the bike on the road, and this allows me to start the bike and let it run.

Thanks, hope you can help with some answers.

Marsh

 

Hey Marsh.....what you describe is the neutral safety switch relay. BTW, what the manual calls "sky blue" as a wiring color, I refer to as light blue:


nss1) OEM safety system NEUTRAL SAFETY SWITCH RELAY.[b/] This relay is also called a starting circuit cut-off relay or an ignition cut-off relay, depending which manual you are reading!

Identification: The Neutral Safety Switch Relay is a small square metal "can" relay, has no paint "dot" by the locking tab, and has the following 4 wires connected to it:

- XJ550 all models, XJ650 all model, XJ750 all models, and XJ1100: a solid light blue wire, a red wire with a white tracer stripe, another red wire with a white tracer stripe, and a black wire with a yellow tracer stripe.

- XJ900RK Seca models: two solid light blue wires ganged together into one terminal slot, two red wires with a white tracer stripe ganged together into one terminal slot, a white wire with a red tracer stripe, and a black wire with a yellow tracer stripe.

NOTE: original relays were always a square metal can style, although they may have been replaced by an automotive style plastic relay. THIS RELAY IS A SPECIALIZED DESIGN AND THE USE OF A STANDARD RELAY IS DANGEROUS!-----it will allow the safety function to be defeated and could result in different operation from what is intended.


HCP431 OEM safety system NEUTRAL SAFETY SWITCH RELAY. For all XJ550, XJ650, XJ750, XJ900RK, and XJ1100 models.
$ 56.95

HCP431VGU OEM safety system NEUTRAL SAFETY SWITCH RELAY. For all XJ550, XJ650, XJ750, XJ900RK, and XJ1100 models, good used condition, guaranteed to work but NOT to solve your problem!
$ 19.95

 

Thanks,
I will be wanting to order one from you but will get back to you after work today. Manuals are confusing I guess .

Marsh

 

Chacal,
That sounds like the right relay you discribed back to me.

HCP431VGU OEM safety system NEUTRAL SAFETY SWITCH RELAY. For all XJ550, XJ650, XJ750, XJ900RK, and XJ1100 models, good used condition, guaranteed to work but NOT to solve your problem!
$ 19.95

How do I go about ordering this part from you? Would like to send a money order if that is OK. Would like to order the used one for 19.95. And give that a try.
Was wondering also if you had the battery side cover for the XJ650 in Red. It snaps on to the frame and hides the Battery. If you had that as well would like to order it to at the same time.
Let me know about how I go about placing the order with you. I am in NY upstate.
Thanks,
Marsh

 

Hey Marsh, I sent you a PM (private message) with the information that you requested!

 

I bought a few parts from chacal for my 83 XJ750K Maxim, his email is info@xj4ever.com and was very pleased with the professionalism, cost (very reasonable) and communications (he let me know when the parts shipped and what was available). I ordered the parts on Monday night and they arrived in Thursday's mail. I will definately by from him again and if your looking for parts I don't think you'll go wrong with him.

Joe
83 XJ750K Maxim original owner 22k miles