I almost pooed myself tonight!!!!

D

davessrx

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Feb 21, 2007
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Location
port washington WI
So here I am with my wife cruising along the woods at 10:00pm and then darkness......NO LIGHTS!!!!!!!!! Then they flash on and then off again!!!! I pull over and hit the relays (blue and white) and nothin' Let it sit 5-10 minutes and lights on. About 3 minutes later out and they are still out. I by passed the white relay with a 20 amp fuse at home and everything is back on.....lights hi and lo, brake, tail, gauges and tach is on......so should I be looking for a short somewhere or is the relay the only "bad" part. If I plug it in and beat the crap out of it the lights will flash on and then go off.....fuse was in for at least 10 minutes w/o failure/blow but that is also with the sled parked. Anyhow I hope this is all it is, scared the crap out of me, well almost!!!!!
 

I just looked at the price of the white and blue relays.......about $60 for the two of them....are they nuts!!! Does anyone know if there is an aftermarket relay that will work....I have a lot of GM relays at work....how many amps goes thru these things.....oh mrviper are you out there????? I don't mind making harnesses, then I can make it waterproof!!!!!
 
Check power and grounds before spending money on relays. If the relay doesn't have the proper ground, it won't be able to hold magnetism to keep the secondary circuit contacts together. It very well could be a faulty relay though. Do you have a headlamp that draws more amps and/or watts than the oem?
 
no aftermarket electronics at all. The ground to the relay is good. And across either powers to the relay to its ground which is supplied by the cdi I have 14 volts running. If I jump either red(12v) to the blue/headlamp switch power wire with a fused jumper(20a) lights and tach are all ok....I know the relay is bad, but could there have been a wire that is chaffed that caused this....my fuse has yet to blow....haven't rode it like this...yet!
 
yup, sounds like the relay is weeds.

But for that price I would do some searching. There has to be an alternative replacement. I'm not familiar with your sled, but is that just a 4 wire relay?
 
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If it is 4 wires it should work with an regular relay from a car etc...can you identify the leads to it?
 
Yes I have a OEM manual. That is how I tested it. Just curious if a normal auto relay would work, I don't know why it wouldn't.....work a try, I have about 10 in my tool box at work!!!!! Hell if they can handle car headlamps,etc it should be fine for my sled.
 
davessrx said:
Yes I have a OEM manual. That is how I tested it. Just curious if a normal auto relay would work, I don't know why it wouldn't.....work a try, I have about 10 in my tool box at work!!!!! Hell if they can handle car headlamps,etc it should be fine for my sled.
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Look under the relay, next to the connectors you have some numbers like 30, 85, 86, 87 are "standard" lightrelays.
Look if it´s the same on the OEM!
 
The yamaha relay and the automotive type ones I have look a lot different, however I do have the manual and the relays I have do have a little schematic on them with those type of numbers....I pm'd mrviper to see what he thinks about all this....After searching other posts on this I am wondering if a chafed wire could've killed the relay.....most of the relays only act up at start up and once on they don't shut off. I am a little paranoid as I don't want this to happen again!!!!
 
Entirely possible that the relay has a burnt coil in it. Are there any type of part numbers on the relay at all?? 99% of the time you can cross it over to a standard relay. Try www.digikey.com and they will be able to cross it for you. I had the 4x4 relays in my Grizzly go and Yammie wanted like $45.00 each for them, I bought them both from digikey for $25 shipped overnight.

Your other option is that there has to be at least 10 Yammies being parted out on this site, see if you can get a couple of relays that way.
 
just ordered yamaha relays. Thought about all the bs in changing the connectors and such and though this site I was able to find a place online that wasn't that bad.....I got both for around $50 shipped to me. I will cut open the old relay to see if anything internal is burnt or rusted. I just hope nothing else is wrong
 
davessrx said:
just ordered yamaha relays. Thought about all the bs in changing the connectors and such and though this site I was able to find a place online that wasn't that bad.....I got both for around $50 shipped to me. I will cut open the old relay to see if anything internal is burnt or rusted. I just hope nothing else is wrong
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Glad to hear you made out ok. FYI, the Yammie relays are the same as any other relay in the way the pins are configured. A non-OEM replacement would have just plugged in to the existing harness if it was crossed over properly.
 
Well after hearing from god himself MRVIPER, I took some wiring apart......found 3 chaffed parts!!!! wiring Under engine, 2 wires by recoil assembly, 1 coming out of stator!!!! He also added it might be worth taking off the seat and fuel tank....how in the #### do you get the tank off!!!! Screws don't want to come out! And it looks as if they mount into the sides of the gas tank. I"ll finish what I have found and reroute that engine harness....under the motor, unreal, what idiot in Japan thought that was a good idea...it getting moved!!!!!! SO ANYONE HAVE WIRES CUT UNDER THE SEAT OR GAS TANK????? I am starting to hate this sled, I work on too much. High performance=High maintenance.
 
LMAO....god??? not hardly, not even close, just a keyboard racer by trade. Its just when you work on these things day in and day out, you quickly learn thru repetition of what problems arise and where to find the source for the problem. No differnt then you working on GM vehicals, you already know whats the problem before you open up the hood from the service writer.......LOL!!! At least ya found the culprit...those relays protect the system from shorts and when you said it(relay) was fine, I knew to look for the short. you have to undo the bolts at back of tank then the 2 screws on sides and top of dash panel, then you can raise up the tank a few inchs and check the tailight harness. :winterrul
 
yea MRKEYBOARDRACER, the 2 side panel to tank screws are well totally screwed!!!! I'd like to check it out. In my testing the relay was bad, however, I cut it open today and no burn spots or rust, it did have some water spots on the coil so maybe that was the issue....but I did find those chaffs too, who knows all I know is when I am done it will be fixed!!! Better be! Also I am rerouting that stupid under engine harness.....how close can it get to the left side of cylinder 1???, of course with plastic conduit around it. I am riding tomorrow so I will recheck all and hopefully it goes well.
 
Well I decided to ride today. Went over 100 miles and no issues....fuse is in place. Must have been that harness that killed the load relay. All is good now, not going to mess with the tank as that 1 screw, that goes into the TANK!!! is screwed!
 
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