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Headlight relay bypass?

Discussion in 'XJ Technical Chat' started by JDS2121, Jul 1, 2016.

  1. JDS2121

    JDS2121 Member

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    Found out last night that my headlight relay on my 81 XJ550 maxim is out. Anyone have experience doing a bypass? I don't intend for this to be a long term fix, just something to work till I get a replacement.
     
  2. JDS2121

    JDS2121 Member

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    Instead of doing a bypass I picked up a cheap $5 headlight relay from O'Reilly's. It's the 30amp 12v one that is in the headlight isle. Removed the original connector shell and individually hooked the blades up to it. There is even an extra blade in case I want to add an 'accessory' that turns on when the bike is on. Works like a charm so far and can even be wedged into the original holder.

    Of course I'm unsure how long this will last, but it does what it should do. Keeps the headlight off until bike starts, keeps it on while bike is on, and when bike is turned off or cuts off it goes out.

    The only thing I don't like is the headlight weakens abit if it drops down near 1k rpms. So for anyone who has a headlight relay go out on the road and needs a quick fix, give O'reillys a shot. Relay is ANZO USA Heavy Duty Relay 30amp 12v S Series. Will update this post if/when the relay does go out.
     
    Alan63 likes this.
  3. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    The factory relay keeps the headlight on once the engine is killed, so long as the ignition is still on. A very handy feature to have at night, particularly if you're laying on the ground by mistake.
     
  4. Hotcakesman

    Hotcakesman Active Member

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    you can bypass it by sticking a wire in the relay housing
    one into the red, the blue and white
    not sure of color
    just cut two wires and then wrap them with tape
    as long as you don't stick a wire in the black aka ground
    you will bypass it
     

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