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relay & cycom elimination on 1982 920

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relay & cycom elimination on 1982 920

PostAuthor: geo » Sat Jan 13, 2007 1:33 pm

Removal of Starter Cut-Off Relays For 1982 920 Virago. By geo from viragotech.com. now called viragotechforum.com


Warning!!! This is a custom chopper mod only!! Eliminating these will cause your start button to be active at all times. If you press the start button while the motor is running, it will still try to start it!! Also you can ride off with the side stand down!!

This is the process to remove the side stand switch, clutch switch, isolation diode, starter cut-off, starter cut-out, side stand relays, and their associated wiring. This makes for a simpler and neater wiring harness and the need to find a place to stash the relays.
I had my wiring harness out on the table and removed the wrapping on the harness. This made easy work of pulling wires no longer used from the harness. It also is a good time to check the other splices in the harness. There are eleven splices in the main harness from the factory!

1) We will start inside the headlight.

Find the small, white 9-pin connector coming from the cycom. Clip the green wire with the blue stripe ( Cut it long enough to ground it. You will ground the wire coming from the cycom, as you are fooling it into thinking the side stand is UP! ). It is the one next to the white w/red stripe. DO NOT clip the plain green wire!!
This will keep the "stand" icon from showing up on the cycom and keep the "warning" light from lighting or blinking.
I plan on writing another article to eliminate the cycom in the near future as a companion to this one so you can scrap the cycom also.


Remove the clutch switch by inserting a small screwdriver in the small access hole to release the tab holding the switch in place. Trace the wire to the green 2-pin connector. Clip both wires on the main wiring harness side of the connector. You may be able to pull the wires through the harness from under the seat.


2) Under the seat

Remove the seat. Remove the side stand switch. At the side stand switch connector (white 3 pin connector with black, blue w/yellow stripe, green w/blue stripe wires) find the green w/blue wire. This runs to the front where you clipped it earlier. You may be able to pull it through the wire harness.

Find the blue w/yellow stripe wire. It goes to a splice in the main harness approximately 5 inches from the connector. The single wire going to the front is one of the clutch switch wires you clipped earlier. You can try and pull it out of the harness. Find the wire going from this same splice that goes to the diode. On the other side of the diode, the wire is sky blue. Approximately 5 inches from the diode is a splice. There are 4 wires spliced here. You want to clip the wire going to the diode and the one going to the starter cut off relay. The two that you want to keep connected are the ones going to the neutral switch and the one going to the front in the main harness to the neutral light.

There are three relays mentioned in the beginning of this article. All 3 are gold colored and say "OMORON" on them. The two with the number "4U8-00" printed on them and have blue connectors. The other has a white connector and has "4H7-01" printed on it. You will note there are several red w/white stripe wires jumping back and forth between the relays. On the relay with the white connector, 2 of these go to the other relays, the other goes to the main harness and goes to the RUN/STOP switch on the right handle bar. Clip this wire, you will connect it to the next wire you will clip so you can judge how long to clip the wire. Find the relay with the blue connector and with the 2 red w/white, black and white w/yellow stripe wires.
Clip the red w/white wire that goes into the main harness. This wire goes to the starter solenoid. Splice the two wires you just clipped. On that same relay, find the white w/yellow wire and trace it to a splice approximately 4 inches from the relay and clip it from the splice. This wire connects the control unit, cycom and relay. It is what some believe to be the tach signal, which could energize the relay and shut the starter down once the engine has started. Find the black wire on the same relay and trace it about 4 inches to a splice and clip from the splice.

At this point, there is only one relay left connected. This relay has 2 wires we need to clip. Find the black wire that goes to the same splice we clipped a black wire for the previous relay. Clip this one also. The black w/white stripe wire is the ignition cut-out if you leave the kickstand down and put the bike into gear. You can either clip it here, or clip it at the TCI 6 pin white connector and pull the excess wire from the main harness. You are now finished!

Warning!!! This is a custom chopper mod only!! Eliminating these will cause your start button to be active at all times. If you press the start button while the motor is running, it will still try to start it!! Also you can ride off with the side stand down!!

This, plus the side stand switch and clutch switch is what you have eliminated form the wiring harness.
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Last edited by geo on Thu Oct 30, 2008 5:38 pm, edited 7 times in total.
Is it break time yet?
If you're not leaning, you're not riding!
If your afraid to scratch it, your afraid to RIDE it!
ride to live another day, live to ride another day!
82 920,2001 YAMAHA FZ1
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"It's ready for just about any sort of on-roading, and, best of all, in the process it can get the rider emotionally charged without ever needing to drag a peg or peg a redline. The Virago is a custom style bike with a wide range of capabilities. There is something very special that relentlessly compels you to just get on and ride- somewhere, anywhere
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PostAuthor: Spindlehead » Sat Jan 13, 2007 8:34 pm

Thank you for the great step-by-step, geo! I am certain I'll use it. I have those relays, along with all of the other junk that was under the seat, stuffed in the stock airbox. If I get rid of the relays, I might have room to put the fuse block and ignition switch in there.

Make sure this gets into the KB, too!
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1982 XV920 Virago choppered up, then "euro-fied" with XV920R tank and and mid-set controls, 2-1 exhaust, mini flyscreen. Gone now to a good home...
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PostAuthor: dr_korb » Sat Jan 13, 2007 11:05 pm

Perfect Timing, Geo....I bet you're a pretty smart guy, too!
Out of Bullets......but STILL disgruntled..... :blast:
'82 XV750J "Bluebelle" :burnout:
'83 XV750K "Yamaharley" Bobber project :eek:
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Re: relay & cycom elimination on 1982 920

PostAuthor: geo » Tue Jan 16, 2007 7:39 pm

CYCOM REMOVAL INSTRUCTIONS FOR 1982 920 BY GEO FROM VIRAGOTECH.COM, now viragotechforum.com.

WARNING!! THESE INSTRUCTIONS ARE FOR CUSTOM BIKES ONLY!
THIS SET OF INSTRUCTIONS IS A COMPANION TO THE ARTICLE ON REMOVING THE SAFETY RELAYS AND SWITCHES. DO THE OTHER ARTICLE FIRST, THEN THIS ONE!


We will start with the "simplest"

SEEMS INFO WAS LOST WITH A BOARD UP GRADE, BUT AS OF 9-16-2011 THIS LINK WORKS
http://viragotech.com/newtech/relay%20c ... 0xv920.htm
Is it break time yet?
If you're not leaning, you're not riding!
If your afraid to scratch it, your afraid to RIDE it!
ride to live another day, live to ride another day!
82 920,2001 YAMAHA FZ1
Image


"It's ready for just about any sort of on-roading, and, best of all, in the process it can get the rider emotionally charged without ever needing to drag a peg or peg a redline. The Virago is a custom style bike with a wide range of capabilities. There is something very special that relentlessly compels you to just get on and ride- somewhere, anywhere
User avatar
geo
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Posts: 3541
Images: 63
Joined: Mon May 26, 2003 9:22 am
Location: northwestern New York, land of taxes Flag
Bike year & model: 82 920



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