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Discussion Starter #1
Okay, got my new wiring subharness (front) in yesterday and hooked the gauge cluster back up so i could see if the 'ol girl would start.. and low and behold ,we have power, but no fuel pump.

After looking around, I notice that the relay holder that normally mounts to the left side airduct tube was not on there. The wires were dangling off the side, and one of the relays were missing. I had the front-most relay attached to the holder, the middle relay unattached (broken tab on the holder), and the plug from the 3rd wire that goes into the rear-most relay, but no relay.

I took the middle relay and swapped cables into the rear position and low-and-behold, i have fuel pump and the ol girl started right up

My question is.. I dont see any differentiation between these "relays".. are they all the same? also, I cant find any info as to what each one of those is? I obviously found the "fuel pump" relay, but what did i unplug to get the fuel pump to work? (middle one)

Also, I dont see the "holder" that snaps into the air tube listed anywhere on the microfiche either, anyone have an idea if its sold as part of the airtube, or if i can get just that piece for a replacement?

Edit: Oh yah, this is an '03 model
 

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According to the service manual, the relay closest to the front of the bike is the fuel cut-off relay, the middle relay is the fan control relay, and the relay closest to the rear of the bike is the engine stop relay.
 

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Ok, I'm looking at the microfiche and according to it each relay is a 20A relay #9 (p/n 38380-MN5-003). It also shows a part for each called "suspension" #8 (p/n 38306-KK4-000) that appears to be the holder for each relay. I found this under the "wire harness" section in the microfiche.

 

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Discussion Starter #4
The first pic helped.. sweet, dont really need the fan control relay then..

As far as microfiche, I guess I missed the specifics of them, but I did see them.. however Im confused on the "holders".. the microfiche pic shows 3 separate pieces, where when I look on my bike, I have one piece w/ 3 tabs that the rubber jackets around the relays fit over..
 

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chkaotic said:
The first pic helped.. sweet, dont really need the fan control relay then..
Are you sure about that? I'd assume without it that your cooling fan would not work.

As for the relay holders, hmmm, I dunno & haven't ever looked at mine. However take a look at the "upper cowl 03-04" section in the microfiche. It lists a part called a "COVER, RELAY" (#15) and the picture of the left air duct looks like it has some tabs on it, possibly for the relays. I'm going to try to do some maintenance on my '03 this weekend and if I get the fairings off I'll get a pic of it to see what the deal is.
 

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Discussion Starter #6


Found the holder im talking about, its on the right side. They show it as part of the intake tube (#14).. see the tabs sticking out of the right side of it? thats what popped apart from the tube itself, and one of those 3 tabs snapped off.. I am guess the "holders" from the previous picture are the rubber jackets that "hold" the relays into the tabs..

So it looks like i'd need a new tube to get this part, and the rubber piece (#15, right next to #14)..

As far as the fan relay, yah, dont need it, as I removed the fan a long time ago..

Edit: Lol.. looks like I sat here too long typing this up, you already said that huh :)
 

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Discussion Starter #8
Yeppers.. might as well put an order in for one and for the aluminum tube.. i got it semi-unflattened but not 100% sure if it will seal real well so better to err on the safe side.. thx again mna
 
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