Safety Relay Stumped

metzlerrc · Jul 30, 2013

Been through a friends 1979 XS 650 multiple times. Have replaced wiring harness(new), new stator 6 years ago. Rotor was going so replaced the whole thing with a PMA setup. Great charges at 13.67 at idle. That never happened before. But the question is since the yellow wire from old setup runs to the safety relay to activate the main headlight, no voltage now supplied to the yellow wire means no headlight. If hooked up to positive side battery, relay is always on ? Would this not cause a draw on the battery, eventually draining it? Any suggestions would be great....

xjwmx · Jul 30, 2013

To make it worse...the yellow was 6v as is the relay it went to. Don't know if higher voltage will damage it.

metzlerrc · Jul 30, 2013

Any way to eliminate the relay?

xjwmx · Jul 30, 2013

Of course. Just connect the headlight to switched 12v.

Grinder · Jul 30, 2013

I read here somewhere that you could hook the yellow to one of the stator leads from the PMA to activate the relay. Try a search.

metzlerrc · Jul 30, 2013

Read through multiple replys and was on my way to that next. Took time off to cool the brain a little. All the talk of bridge rectifiers, three legs, 6 volt / wild voltage... Plugging along

metzlerrc · Jul 30, 2013

Took a quick voltage read and came out with 6.54 volts, working on a splice wire to see if it works.....

metzlerrc · Jul 30, 2013

So far no smoke no heat and the relay seems to be working with a splice wire in one of the three stator leads..... will run more test on voltage later, time for a break...

metzlerrc · Jul 30, 2013

Ok enough for the night. Spliced in a lead into one of the 3 legs coming from the stator. Seems to have no effect on voltage output. At idle about 12.45, at 1500 about 12.99 to 13.1. Any thing over voltage starts climbing to a max output of 14.49 give or take. Safety relay works as before. No smoke, no heat. We'll see what tomorrow brings with the pamco unit.... thanks for the input...... Time for a vodka tonic.....

Brian902 · Jul 31, 2013

Perhaps this will help;

metzlerrc · Jul 31, 2013

This was not one of the issues. Every thing worked except the light portion of the relay. Started fine ran fine but no headlight. Have run for a while with a splice in the stator(PMA) leads and seem to have no problems yet. If there had been an issue with the started portion of the relay would have taken that route. Will file that one for later when the relay fails totally as all old things are prone to do. Just finished up with the PAMCO ponitless system but before firing it up one more time going to re-adjust the valves. Not that it matters but will update later. Thanks

metzlerrc · Jul 31, 2013

Sync'd carbs, checked valves, installed PAMCO unit. custom mount to move horn between downtube's, custom mount for the dual coil set up, below the original coil mounts, basically where the horn was. Like the way wires from coil go over and around both sides of the head before termination to plugs.INstalled new rubber mounts for the bars, tightened chain. Was careful on set up, fired right up. even the timing was spot on. Good days work and a great evening ride.....

Dumbmonkey · Jun 22, 2016

Hi,
From what I'm seeing here, I can just splice the yellow into one of the wires coming off the new PMA stator, and the relay will work as before without issues? Seems like an easy enough solution . My new PMA stator only has 2 yellow wires coming off of it, does anyone think that would be an issue?

Safety Relay Stumped

metzlerrc

XS650 Member

xjwmx

XS650 Guru

metzlerrc

XS650 Member

xjwmx

XS650 Guru

Grinder

XS650 Guru

metzlerrc

XS650 Member

metzlerrc

XS650 Member

metzlerrc

XS650 Member

metzlerrc

XS650 Member

Brian902

XS650 Junkie

Attachments

metzlerrc

XS650 Member

metzlerrc

XS650 Member

Dumbmonkey

XS650 Enthusiast

Similar threads