relay fault and wiring advice needed.

[dirk]

Hi
just brought a 98 1200 3cv with a wiring problem.
when you hit the start button there was no noise at the solenoid and the oil and ignition lights both light up.

i put a spanner across the solenoid with ignition and run/stop turned on and the motor ran. after a day of faultfinding and reading i unplugged the main relay and the fault went away on the dash.
i have now taken a wire directly from run button to the solenoid bypassing the loom and the bike is running off the button. relay has been unplugged.

so my question is, by removing the main relay what changes will that of made. will the pump only run for the initial 5second prime then turn off. will it effect anything else.
might sound a bit drastic but i always prefer to remove anything other than the basics once i get into a loom.

cheers for any feedback...dirk

[Pat Conlon]

Check your handlebar run/stop switch to be sure it's in the "run" position. If the switch is in the Run position, do a continuity test on this circuit. Your run/stop switch may be faulty.

The clue you gave me was the 2 red lights (oil level, fuel level) coming on when you thumbed the starter button. This happens when the run/stop switch is in the stop position.

As outlined in the owners handbook, this is how you check to see if the 2 dash bulbs are working.

I was not aware the FJ's were produced in '98, I assume you have an '88 (not imported to us here in the USA)

[dirk]

sorry 1988.
the run/stop was definately on as the pump primes when i turn it on.
thanks for the reply

[Pat Conlon]

Ok then, does your '88 have a side stand safety switch?
Some do some don't.
If so, try following the wires up to the plug (left side) unplug and with some spade connectors attached to a short piece of wire, jump the 2 male prongs on the plug. Close the circuit. See if that does it.
Don't cut any wires, use the jumper at the plug.

[aviationfred]

 When you push the START button, the starter solenoid should click (closes), sending 12v to your starter. There is a Blue/white wire that comes from the START button to the main relay, then from the main relay to the starter solenoid.

When you turn on the ignition switch, do you here the fuel pump clicking? If it does click a few times and then stops, I will say the problem with the starter switch/solenoid is a wiring issue.

If the fuel pump does NOT click when you turn on the ignition, I will say that you have a bad Main relay assembly.

will the pump only run for the initial 5second prime then turn off The fuel pump should not run at all without the Main Relay installed

The Main Relay assembly has the following components that go through it.

1. Fuel reserve switch
2. Oil level switch
3. Start switch
4. Clutch switch
5. Side stand switch
6. Neutral switch
7. Fuel pump relay
8. The ignitor Unit


Fred

[dirk]

thank you for the replies. much appreciated.


my pump does not prime when i turn the key. it primes when i flick the run/stop.

can you tell me where the main relay is located.i cannot seem to find a answer to this.
i have been classing the one on the left front under the fairing next to flasher relay as main relay.
i have removed this and stripped out all the loom attached to it and the bike still started with a spanner across the solenoid.
either i have the wrong relay or someone in the past has worked around it.

there are a lot of connectors and bypasses in the loom.this and the general age and state of the loom is why i decided to remove the relay and safety features to make it simply run and nothing more. i,m not hacking at it without thought. i spent a full day trying to fault find the bike before i went down this path and was getting nowhere.

will report back..cheers

[aviationfred]

The Main relay is #3 in the diagram. Left side mounted on the forward sub frame just above the air scoop

https://www.partzilla.com/catalog/yamaha/motorcycle/1989/fj1200w/electrical-1


Fred

[dirk]

thank you

mine does not need this too run if you jump the solenoid.
last owner must have really cut into the loom

[aviationfred]

thank you

mine does not need this too run if you jump the solenoid.
last owner must have really cut into the loom

my pump does not prime when i turn the key. it primes when i flick the run/stop.


My advise is..... purchase a NEW Main Relay Assembly P/N 2UJ-81950-00-00 and then figure out where the previous owner modified the wiring. The safety mechanism of the side stand switch and the clutch switch should always be allowed to work.


Fred

[Pat Conlon]

It sounds like Dirk has 2 options
1) restore the oem function of the wiring harness, or
2) throw away the oem harness and start fresh.
If you decide #2 here is a minimum wiring harness the race car owners use to power the FJ engine.
http://www.fjowners.com/index.php?topic=16278.0

[dirk]

cheers for all the help.

i have ordered a loom so i can keep all the original features.

one thing..when i was running it the clutch pushrod flew out. i have pushed it back in but have read it might not locate properly and i might now have to do something on the clutch side. is this true?

[ZOA NOM]

Did it kill a cat? Most of us have killed a cat when the clutch pushrod flew out. I believe there is a ball in there as well. Might try to find it if it also came out.

[FJmonkey]

The ball has not been reported to come out with the push rod. Mine did not come out. Just put the rod back in, clean up the oil, deal with the cat. Then for future events consider a process to prevent it. I put the key in the house when I remove the clutch slave. Tape over the key, any kind of reminder while the slave is off.

[ryanschoebel]

The ball has not been reported to come out with the push rod. Mine did not come out. Just put the rod back in, clean up the oil, deal with the cat. Then for future events consider a process to prevent it. I put the key in the house when I remove the clutch slave. Tape over the key, any kind of reminder while the slave is off.

To be fair, dealing with the cat is the hardest part. It only took me one time of shooting that spear, and I have never forgotten it again. It kinda sticks in your memory I think 

[dirk]

 
cheers for that.

cats know to avoid my house. i work for a staffordshire bull terrier rescue. have 4 in at the moment.

new battery oil and filter turned up today.just waiting for the loom. i will hopefully be sent a usable one.

ive been looking over the simple wiring diagram. mine has no vacuum advance so it looks to me like a simple case of pickup wires ,coils ,positive ,negative plus loop the safety circuit back to negative. plus wire in a pump and solenoid. seems very simple. am i missing something?

thanks for all the feedback