#1: relay & cycom elimination on 1982
920 Author: geo,  Posted: Sat Jan 13, 2007
2:33 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
6:38 pm; edited 7 times in total |