how to wire harley starter relay

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

Audio Oil Pressure Alert Relay Installation Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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Step 1) Wire Connection: Using 18-gauge automotive wire, connect the audio alert relay as shown in the Wiring Diagram – Figure 1. • Connect the supplied wire from #3 terminal on the audio alert relay to the oil pressure switch post. Note: The supplied wire is not reversible. The eyelet end must hook to the oil pressure switch. • Connect a wire from #2 terminal on the audio alert relay to the ignition switch post that receives power when the ignition switch is first turned on. • Connect a wire from #1 terminal on relay to the positive side of existing horn, or alternate sound device. • Note: The audio alert relay uses the oil pressure switch as its ground. On most motorcycles, this audio alert relay can be installed easily under the dash. Figure 1- Wiring Diagram Cot a Oil Pressure Switch Ignition Switch Audio Alert Relay 2 1 3 load Horn + + – Caution: Make sure all connections are insulated away from potential grounds. Do not disconnect any existing wire. Step 2) Testing : Turn ignition switch on and ensure oil pressure light is on. Leave ignition switch on. Wait 30 sec (T1) and ensure the audio alarm sounds for ½ second (T2). If the electrical test is successful, proceed to Step 3. If not, you may have to use a pezio alert in place of the horn. (Which is available at most Radio Shack stores.) If audio alert still doesn’t work, consult the wiring diagram and recheck all wiring connections. Verify timer set points have not been altered. If problems persist, contact us at (518) 884-9591. Step 3) Mount relay switch: Use standard zip ties (not provided) or similar means to mount the relay to dash mount post or dash base. Note: The timer relay can be mounted almost anywhere on the bike that will not be exposed to direct rain or weather

2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

HONDA Ground Effects Installation Instructions

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Filed Under (Honda) by admin on 10-11-2010

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Wiring Installation: 1. Remove the four M8x1.25 socket head cap screws from the seat and remove the passenger handles and seat. 2. Remove both rear side covers, and right front side cover. 3. Remove the two M3 Phillips head screws and two trim clips from the right front storage pocket. 4. Place the three relays of the Ground Effects Ground Effects Ground Effects Ground Effects wiring harness underneath the relay box. 2001 2001 2001 2001 — – 2005 MODELS 2005 MODELS 2005 MODELS 2005 MODELS Route the long end of harness (blue wire and orange wire), behind the fuel tank to the brake lines. The shorter section of the harness will end at the brake lines. Continue along the brake lines to the main harness of the motorcycle to the shelter, then up through the shelter to the pocket area. 5. Locate the harness connectors under the pocket. Go to step 6. 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS 2006 & NEWER MODELS Route the long end of harness (blue wire and orange wire), under the relay box and connect to the Positions Relay. 6. Connect the orange wire to the orange wire with white tracer using a scotch-lok connector. Connect the blue wire to the light blue wire with white tracer using a scotch-lok connector. 7. Route the red and white wires behind the fuel tank, along the left side wiring harness to the fuse box. 8. Connect the RED wire with eyelet connector attached, to the positive side of the accessory terminal in the fuse box. 9. Connect the WHITE wire to the negative battery terminal. 10. Connect the brown wire with white tracer to the brown wire with white tracer (tail relay in relay box) using a scotch-lok connector. 11. Route the orange wire with black tracer and the white wire behind the fuel tank, with at least 6 inches of wire left hanging below the bike. 12. Reinstall the right fairing pocket with the two M3 Phillips head screws and two trim clips. 13. Replace the right front side cover and the right and left rear side covers. 14. Replace the seat and passenger grip handles with the four M8 x 1.25 socket head cap screws

BMW R1200GS Dual Function LED Running Lights and Flashing Brake Lights installation instructions

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Filed Under (BMW) by admin on 08-11-2010

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The flasher is set to flash continuously as long as the brake is applied. To convert to a 5 second flash and then stay solid while the brake is applied, cut the green wire loop on the flasher. Use electrical tape to protect and secure the green wires to the other wires. 2. Remove the rider’s seat. Locate the wire bundle that starts at the rear of the motorcycle. At the most accessible spot carefully remove 3″ to 3½” of protective wire loom. I know, I know…it’s really beautifully done. Cowboy up! Take it off! 3. Mount the flasher in a location that will not crimp wires or interfere with the other bike assemblies. Locate the +12 volt wire ( GRAY wire with BLACK stripe and YELLOW banding) from the brake light Attach the kit RED wire to the brake light positive wire using one of the Posi-Tap connectors in the kit. 4. Locate the Ground wire ( BROWN wire) from the brake light. Attach the kit BLACK wire to the motorcycle ground wire using a Posi-Tap connector. 5. If you have a Fuse Block with ignition switched relay installed, route the Hyper-Lite GRAY wire to a fused circuit on the (relay activated) fuse block . 6. If you do not have a Fuse Block installed, find the alarm circuit connector under the seat . The alarm circuit has a rectangular connector and five wires, White with Black stripe; White with Brown stripe; Red with White; Brown with White; and Green with White stripe. Use a Posi-Tap to attach the Hyper-Lite GRAY wire to the green wire with white stripe. Pull the wire loom back from the wire. Tap into the wire with the Posi-Tap provided. . 7. If using the Hyper-Lite License Plate Mounting bracket, install it now. OR: Clean the side facing reflectors at the rear of the bike with alcohol. Mount the LED modules vertically on the reflectors so that the LEDs point straight back. Press in place for about 5 seconds. The tape can be used only once! If you goof, new tape is required. 8. Route the BLUE and BROWN wires from the flasher and the LED modules. Trim the Blue and Brown wires to remove any excess wire . Use a Posi-Twist to connect the 3 BLUE wires together. Use a Posi-Twist to connect the 3 BROWN wires together. (see Posi-Twist Connector instructions)

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