mixed up headlight -vs- starting relay...Please Help?

Well, I have two 1980 xj650 maxims I'm fixing up and there's some confusion on which relay is where and attached to which wires... The yamaha service manual says the Headlight relay is under the tank below the frame backbone attached to four wires being: black,white,blue/blk and red/yel.
But The wires there are red/w, red/w, lt.blue/blk and blk/yel. ( which it says is for the starter relay located under the left sidecover by the CDI box...
9
Somethings Backwards in the manual ? The relays are Omron #'s 3H5-00 ( yellow tab, Headlight ?) and 4H7-01 ( starter, safety ?) These bikes don't have the kickstand switch or a relay for one.
Please recommend which relay goes where and to which wires?
Thanks, Regan.

 

well...lots of lookers but no suggestions? looks like I "am" smarter than a fifth grader... The Yamaha manual is wrong in its location but correct with the wiring color codes...

 

Yeah, I was gonna suggest that the color coding on the wires would be your best guide. The locations MAY NOT be wrong in the book, you may have a case of the PO blues and don't know it...

 

Relays:


ssr1) OEM safety system SIDESTAND SAFETY SWITCH RELAY.

Identification: The Sidestand Safety Switch Relay is a small square metal "can" relay, has a blue paint "dot" by the locking tab, and has the following 4 wires connected to it:

- XJ550 all models, 1982-84 XJ650 all model, XJ700 all models, XJ750 all models, XJ900RK Seca models, and XJ1100 models: a solid black wire, a red wire with a white tracer stripe, a black wire with a white tracer stripe, and a blue 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NOTE: original relays were always a square metal can style, although they may have been replaced by an automotive style plastic relay.


Neutral Saftey Switch Relay:

nss1) OEM safety system NEUTRAL SAFETY SWITCH RELAY. 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.



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.



Turn Signal Relays:

tsrs1) OEM turn signal system FLASHER RELAY. In order to design a "self-cancelling" turn singal system, Yamaha chose to use a simple but very different style turn signal Flasher than what is used in almost all other vehicle applications. Of course, the unique design of this flasher unit makes it, let's say, "pricey" to say the least! However, if you want your self-cancelling feature to work then you'll have to use this original flasher. NOTE: you can use generic aftermarket mechanical or solid-state flashers in place of the original flasher, but the aftermarket flashers will prevent the self-canceller feature from operating.

Also, if you substitute LED bulbs in your turn signals for the standard incandescent bulbs, then the stock flasher (which is mechanical) will not see enough of an electrical load to be able to flash correctly, if at all. In such a situation, the stock flasher is not defective, it is just designed to operate at a much higher voltage draw than LED lights provide. In such a situation, you would have to replace the stock flasher with an aftermarket solid-state flasher, which will also defeat the self-canceller feature of the original system.

Identification: The Flasher is contained in a large, rectangular black hard-plastic "box" housing, and has the following 3 wires connected to it: a solid brown wire, a brown wire with a white tracer stripe, and a yellow wire with a green tracer stripe. This applies to all models except XJ700 models.

The Self-Canceller Relay is a rectangular, sealed, rubber-coated box with 6 wires coming out of it into a connector: a solid tan wire, two (2) white wires with a green tracer stripe, a yellow wire with a green tracer stripe, a yellow wire with a red tracer stripe, and a white wire with a red tracer stripe.

By the way, the self-canceller operates off both time AND distance measurements to determine when it should cancel the flashers.....a minimum of 10 seconds time and 150 meters (about 400 feet) distance. BOTH criteria must be met before the canceller releases the signal flasher.



ADDITIONAL RELAYS:

1100 models also use a 2-pin Hazard Flasher Relay, and XJ650 Turbo models use a 4-pin Fuel Pump Relay, and both the 1100 and 650 Turbo models use an Emergency Stop relay (which I don't have the wire codes or relay ID info available for currently).

 

Just to clarify that Regunner is correct that the relays are shown backwards in the factory manual in some of the drawings.

Chacals info is dead on.