2011-09-27 Headlights out

Just tracked down the intermittent Low beam loss as the headlight relay. It just started happening and seemed be more likely to happen when the bike was stationary and/or not running. Well it appears that the headlight relay took a dump. After tracing and buzzing out related wires it looks like the headlight relay is "sticky", since the slightest tap on the case makes the low beams come alive again after switching from Hi to Low or starting up the bike.



Now the real problem, how the $&@*# to identify what part number to order? Damn it sucks not having Gary McCoy around.



I've checked the Bin-O-Facts and Googled the Forum, but have not come up with the part number.



Does anyone have any suggestions? There seem to be four listings for Relay Assembly in the "Electrical 2" microfiche but no identification of which relay is which. Since there's only one headlight relay that still leaves # 22, 26 or 27 to choose from.

Tag....Description................................................Req.......Price

22......SKU: 5VK-81950-30-00.....RELAY ASSY........1..........$35.62

24......SKU: 5EA-81950-20-00.....RELAY ASSY........2...........$19.72

26......SKU: 5JJ-81950-10-00.......RELAY ASSY.......1...........$18.31

27......SKU: 5DM-81950-00-00.....RELAY ASSY.......1...........$12.85

 

There are two headlight relays. One relay switches the headlights on/off. This relay is located on the right side just forward of the battery and below the brake light relay.



The other relay which toggles between high and low beams is located on the left side, buried up under the cowling.



I can't identify this relay from the Yamaha parts drawings.



Your problem could be something other than the relay. It might be as simple as a loose connection somewhere between the high/low beam toggle switch on the left handlebar and/or at the relay. The relay coil must be powered to get the high beams. When unpowered the default position is the low beams. 

Thanks for the info, yes I'm referring to the relay that switches b/w Hi/Lo, the one with the Blue/Black control wire. I too was not quick to jump to the conclusion of a faulty relay since it's usually not the case. However, the Hi/Lo switch works fine, the wires are not loose or broken and even slightly tapping on the relay when switched from Hi to Lo makes the contacts work, turning on the Lo beams. I still don't know how to figure out which part number to order though. 

The relays should be laid out in an anatomically correct fashion. Which number relay did you tap to flicker your lights?







 

That's the problem, on the Gen II the Hi/Lo relay is located all by itself on the LHS of the bike (when sitting on the bike), behind the left headlight, under panel C (starting from the Batt cover panel). 

The fiche that dealers have are much more detailed. Call a dealer, talk with the parts guy and get the relay number, then be horrified at the price he quotes and hang up. Now, take that P/N and go shop for best price.







 

Thanks Alan, believe it or not I just called Yamaha Sports Plaza (they have 30% discount on all Yamaha OEM parts) and the Parts guy had no clew either. He said he's going to go into the workshop and speak with the techs and try to look at a bike to see if they can figure it out - pretty ridiculous huh? 

5EA-81950-20-00



Most likely this part. The hi/lo relay and and brake light relay appear to be the same -- single pole double throw. 

Bump 

Dang. No progress on this? Am I going to have to figure it out all by myself? 

The parts guy over at Yamaha Sports Plaza confirmed that they have no way of figuring out which part number this relay is without actually looking at the numbering printed on the top of the relay. I wanted to wait until I spoke to him again on Monday but since you're in a hurry here's the info he told me the parts department would need to determine the correct Yamaha part #. So until I can find out the actual part#, you can just quote this to the the parts guy: G8HN-1C4T-DJ

So based on the number printed on the top of the headlight relay it appears that the correct part# is: SKU: 5DM-81950-00-00

JamesK, on 08 February 2010 - 08:43 AM, said:

Ok. I can now 100% verify that the part number quoted by JamesK is correct. Comes complete with rubber mounting thingie and all.