Post by herocomplex on Sept 28, 2006 0:02:02 GMT -5
Hi all, the headlight on my 78 XS isn't working and I've tracked it down to the safety relay. I've tested the relay and both sides connect when it is supplied with power via the yellow stator wire. When the bike is running, however, there is no power coming over that oh-so-special yellow wire. The stator is new and is charging the battery just fine. What might be the problem here? When I jump power to the yellow stator wire the light comes on.
Strangely, when I test the yellow wire with the bike off and the safety relay disconnected I read around 5 volts or so. That just seemed weird to me, but with the relay connected the potential is gone. Granted, I don't completely understand what's going in the safety relay except for the basic relay operation. Any help would be greatly appreciated.
There should be no voltage on that wire at all with the bike off. So something strange is happening. The yellow wire is a tap off off the stator windings and has a diode inline to provide a 7-9 volt DC signal to the relay that tells it the engine is running. If that diode is blown you will get an open in the wire to the stator and no DC signal to the relay like you describe. Check for continuity between the yellow and any one of the three white wires at the stator main harness plug. If no circuit is there then you have a cut wire or blown diode. It's usually the diode. Look at the 1980 XS400 electrical page on the Yamaha online parts catalog and you will find a diode that will work. Find the old diode where it is taped into the harness and replace it.
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