The Yamaha Road Star Warrior Forum

I put a new battery in today and while stuffing all the wires back into place I found a red wire that goes from the fuse block beside the battery box to a relay. This wire has a fuseable link in it and the fuse is blown but the bike runs perfectly. All the lights funtion properly, all the safety switches are working ( clutch Kickstand etc...). I dont have any horns but this wire is way to heavy for that anyway.  Anyone know what the wire is for? As far as I can tell its the only wire under the seat with a fuse link in it.

Is it this red wire?  I never really looked at this fusible link.  What fuse in the fusebox is it coming from?  I don't think its related to the horns either since back when I was considering a replacement horn I remember the electrical drawing shows the horn switch feeds the horns directly (so to speak) and the power comes from the same circuit as the headlight and signals.  Odd that neither of your horns works though.  You've got me curious so I'll look at my bike next chance I get.  In the meantime I'll almost bet someone like Alan has already traced it, identified it, photographed and x-rayed it, done a detail drawing and has all the technical info on the wire strand and fusible link already on his computer!  I'm sure we can count on Alan to chime in and tell us what it feeds and why it could possibly be blown but not affect anything (which is a bit curious!).

That looks like the wire I am talking about. It does not go to a fuse in the fuse box, it is bolted directly to the fuse box. It almost looks like a lead coming out of the fuse box. I will try to take a picture this morning and post it. as far as my horns go I mean I litterally dont have any horns as in they were removed. I just let those reineharts scream to get peoples attention.

 I looked closely at it today and I see the main battery cable (pos) comes off the battery, and goes directly over to the fuse box. The lug that the main cable connects to on the fuse box has another smaller red wire connected to it as well. So I have 1 lug 2 wires both with eyelet connectors. The smaller wire runs up to what appears to be some sort of relay. The smaller wire also has a fuse link with a blown fuse but nothing is showing up as not working. Sorry I dont have a picture, camera is not working.

Yes, in my old memory the red wire with the fusible link comes off the battery/fusebox connection point and goes to the top relay on the relay rack, is that what you are saying?  I remember that relay is only referred to in the service manual as 'relay' while all the other relays say what they are, like "turn signal flasher relay" or what ever.  Next time I take it apart (a few weeks away) I'll have a closer look.  You've got me interested.

hdwarrior102:

 I looked closely at it today and I see the main battery cable (pos) comes off the battery, and goes directly over to the fuse box. The lug that the main cable connects to on the fuse box has another smaller red wire connected to it as well. So I have 1 lug 2 wires both with eyelet connectors. The smaller wire runs up to what appears to be some sort of relay. The smaller wire also has a fuse link with a blown fuse but nothing is showing up as not working. Sorry I dont have a picture, camera is not working.

Yes this is exactly what I'm refering to. I found that in my manual also or I should say I found  the lack of information. I'm glad they pointed out the fact that it is a relay. I guess I could start unplugging wires from it and see what quits working. Then I'll know what it relays but then again there is no power going to it now.  I was just curious about it anyway. I guess if it wasnt important enough to say what relay it is then maybe its not that big of a deal. I would stick a new fuse in it but I dont want to fry anything. Something made the 20 amp fuse thats in it blow.

I sent you a PM too, sorry I have not been able to dig deeper, I hope to be home this weekend for the 3-day.  Here's one link for the circuits from the battery: http://rswarrior.com/files/folders/reference/default.aspx

There's also a color diagram someplace and if you magnify it on-screen you can trace all the circuits that come off the battery to see where they go.  I know its in the service manual so if you have an e-copy look there for the one in color.  AlanH also notated a copy it might be in his gallery I don't know.  Either would be helpful.  If you have it figured out let me know, and tell me what you learned okay!

Arizona Warrior:

Yes, in my old memory the red wire with the fusible link comes off the battery/fusebox connection point and goes to the top relay on the relay rack, is that what you are saying?  I remember that relay is only referred to in the service manual as 'relay' while all the other relays say what they are, like "turn signal flasher relay" or what ever.  Next time I take it apart (a few weeks away) I'll have a closer look.  You've got me interested.

hdwarrior102:

 I looked closely at it today and I see the main battery cable (pos) comes off the battery, and goes directly over to the fuse box. The lug that the main cable connects to on the fuse box has another smaller red wire connected to it as well. So I have 1 lug 2 wires both with eyelet connectors. The smaller wire runs up to what appears to be some sort of relay. The smaller wire also has a fuse link with a blown fuse but nothing is showing up as not working. Sorry I dont have a picture, camera is not working.

hdwarrior102:

Yes this is exactly what I'm refering to. I found that in my manual also or I should say I found  the lack of information. I'm glad they pointed out the fact that it is a relay. I guess I could start unplugging wires from it and see what quits working. Then I'll know what it relays but then again there is no power going to it now.  I was just curious about it anyway. I guess if it wasnt important enough to say what relay it is then maybe its not that big of a deal. I would stick a new fuse in it but I dont want to fry anything. Something made the 20 amp fuse thats in it blow.

The relay in question is quite specific and called out in the wiring schematic - Item 7 - Starter Relay which is below the Main Fuse: http://www.fileden.com/files/2008/1/1/1673654/Warrior/Warrior%20Schematic.pdf

 Arizona Warrior ... FYI, the enhanced Warrior wiring diagram is located here: How To's and General Maintenance Tips  underneath

Here are the specifics and location of the OEM as built fuse location edited by me from an earlier topic: