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xj600, pre diversion ,safety relay

Discussion in 'XJ Technical Chat' started by bensalf, Nov 8, 2022.

  1. bensalf

    bensalf Well-Known Member

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    hi , all.
    dunno, if anyone can help me ,
    i am renovating the wiring, harness and the plug in components of the bike lights, flashers ,guages, switches etc, all components now work ( everything is off the bike)
    but it is missing the safety relay, or (diode block) as it is sometimes called, i cant find one on ebay, Len does'nt list the 600. it seems the 600 safety relay may be unique, unless anyone can match it up with theirs from the following pictures.
    i could have a go at making one up, as i'm a "long retired" electrician, if i could find out the internal components and connections.
    it apears from the bikewiring diagram that the safety relay incorporates several different aspects, of safety, namely, the test circuit for the oil level dash light ( via start button) . neutral light and clutch interlock, as well as allowing starter relay to energise,
    so , does anyone have any drawings of the internal " wiring" of this relay,
    IMG_0954.JPG IMG_0954.JPG IMG_0955.JPG IMG_0956.JPG IMG_0957.JPG IMG_0958.JPG
     
  2. Rooster53

    Rooster53 Well-Known Member Premium Member

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    This is in the service manual, but I suspect you already have it. This version looks to function much like the others except Yamaha decided to combine the starter cutoff relay with the diode block

    upload_2022-11-9_7-19-30.png
     
  3. bensalf

    bensalf Well-Known Member

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    thanks rooster, that gives me a good insight to the internal workings, though that diagram is for the later "diversion" model, which started production in 1992.
    my "pre diversion" ended production in 1991.
    red/white wire and black/ red wires are missing from the diagram, but ill see if i can transpose them, interesting ,the blue /white wire 3rd from left doesnt go anywhere
     
  4. Rooster53

    Rooster53 Well-Known Member Premium Member

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    Maybe this one, it is close to the same as above but has the different colored wires like you posted. It doesn't do as good a job of showing where the wires connect but between the two it could be pieced together
     

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  5. bensalf

    bensalf Well-Known Member

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    thanks so much Rooster, i'm sure i can make something from those 2 diagrams, wont be around for a week now but i'll try when i get back ,thanks
     
  6. a100man

    a100man Well-Known Member

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  7. bensalf

    bensalf Well-Known Member

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    thanks everyone for the help and diagrams , i'm sure i can make one , from the information supplied, i have various relays and diodes
     
  8. bensalf

    bensalf Well-Known Member

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    hi all again,
    following on from this thread from about a month ago , i managed to make a diagram of the safety circuit , and internal wiring of the safety relay, for my xj600. thanks to Rooster53 and a100man for the diagram's, heres the safety circuit


    IMG_0993.JPG

    so , i managed to make up a safety relay ( diode block ) using some components i had lying around , so i got a small electrical connector box ,and fixed them in

    IMG_0984.JPG

    only thing i could'nt find anywhere was a "9 way omron connector, to allow the new relay to be plugged into the harness, but i could find a 13 way one, which will plug into the harness plug by disusing the outer 2 pins on each side.

    IMG_0985.JPG IMG_0986.JPG IMG_0987.JPG



    IMG_0988.JPG
     
  9. bensalf

    bensalf Well-Known Member

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    so i plugged the new relay into the harness on the bench, with all electrical components plugged into the harness , and powered it up from a spare car battery ,i have , and BINGO, everything works great tried all the safety features, clutch interlock, neutral light , and oil level light test circuit.
    everything works as it should, so thanks for all your help,
    i hope this may be of help to any others
     
  10. a100man

    a100man Well-Known Member

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    Good work and a great reference.
     

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