clicky starter self fix and headlight relay

**GRAYWOLFGRAPHICS** · 11-03-2007, 03:32 PM

OK i have seen the questions on here a million (maybe less) times. "Where do i get a clicky starter fix?" or "How i run a relay for my headlights or offroad lights?". This will be my first "how-to" here so be patient.

1, "WHAT IS A RELAY AND WHY USE IT"

A relay is typically used to control a component that draws high amperage. The relay allows full power to the component without needing a switch or wiring that can carry the amperage. The switch only controls the relay. The relay then provides a direct connection to the battery.

2, "WHAT CAN A RELAY BE USED FOR"

A relay can be used to control any component that draws high amperage. I personally have used relays for elect fans, starters, air horns and lights but the uses are about endless.

3, "HOW DO I CONTROL A RELAY" (pay close attention here and you will be amazed at how simple this is!!!!!)

A relay can be switched by a positive or a negative source. (Yes i said negative source or "GROUND START" see note 5 below) A relay is simply a remote switch controlled by another switch. By applying power to a positive start relay you are simply telling the relay to close the switch within the relay. A ground start relay already has a positive source supplied and you are closing the circuit by supplying a ground (ie a thermostatically controlled fan or horn)

4, "WHAT THE ^%(*& ARE ALL THESE CONNECTIONS"

the power connection (86) and ground(85) connection in the relay (85) are the control or low amperage side. These are the ones that control the relay. (86) would be the one connected to the wire that you remove from the starter for the clicky fix and (85) would be a chassis ground. When 12v is applied to the control side (86) it closes the switch or CONTROLLED side of the relay.

The power SUPPLY connection (30) and switched power or load (87) connection in the relay. The power (30) connection should go to a fused power source with significant wire and fuse to carry the load of whatever you are trying to power. You can go straight to the battery with either an inline fuse
or a fuseable link (not easy to replace on the trail). I suggest the inline fuse. The load (87) connection goes to whatever you are trying to power(ie CONNECTION WHERE YOU TOOK THE OTHER WIRE OFF THE STARTER FOR THE CLICKY FIX, lights, air horn, compressor, elect fan ect).

5, "WHAT IS A GROUND START CIRCUIT AND HOW DO I USE IT?"
This is pretty simple also. As you know you need 2 things in a circuit. Power and ground. In a "GROUND START" circuit the power connection (86) will have constant power and ground(85) connection will go to you switch or control. For example: Wiring electric fans, (86) will have fused power preferably from a source that is powered with your ignition switch in the run position. (85) will go to a temperature switch in your block that grounds out at a set temperature. Supply (30) and load (87) will be as above. Keep in mind the load (87) will only supply the fans with power. You will still need to ground the other lead on the fan motor.

6, MOST IMPORTANT BASIC WIRING TIP

This is pretty simple BUT OFTEN MISSED POINT. Do not run big wire as a lead to anything if you are going to skimp on the ground. A ground is just as important as the power supply (RUN THE SAME SIZE WIRE). Clean your grounding surface before attaching the ground and make a secure connection.

7, CAN I RUN HI AND LO BEAMS WITH A RELAY??? YES

This is also pretty simple. as you noticed above we didn't use the powered off connection (87a). If you so desire you can run 2 relays with one sending power from its switched (87) to (30) on a second relay. The second relay would work as your hi-lo relay

7, CAN I RUN HI AND LO BEAMS AT THE SAME TIME WITH A RELAY??? YES

This CAN BE DONE BUT NOT RECOMENDED WITH THE SAMI ALTERNATOR OR FOR BEGINNER WIRE NUTS. All you have to do is add a diode to the above circuit. Radioshack can supply you with the correct diode. A diode is easily understood like a one way swinging gate. if you have one this will be VERY clear. when you go out the gate it swings easily and out of your way, BUT when you are in a hurry and try to go the wrong way you end up with a face full of of wood or chainlink. A diode only allows power to go one way.

LAST BUT NOT LEAST HERE IS WHAT EVERYONE HAS BEEN WAITING FOR THE "CLICKY STARTER FIX"

GRAYWOLF GRAPHICS WILL NOT BE HALD RESPONSIBLE FOR AND DAMAGE DONE WHILE ATTEMPTING THE ABOVE HOW-TO. IT IS FOR INFORMATIONAL USE ONLY. PLEASE ENJOY THIS HOW-TO AS IT IS INTENDED FOR THOSE WHO LIKE TO SAY "I DID THAT" BUT IF YOU STILL FEEL SQUEEMISH ABOUT ATTEMPTING IT YOURSELF THE CLICKY FIX CAN BE BOUGHT FOR ABOUT $15

**johngat** · 11-03-2007, 08:03 PM

Nice write up

**Itsmejoe231** · 11-03-2007, 10:15 PM

Nice!!

I am going to move this in the FAQ section.

**GRAYWOLFGRAPHICS** · 11-03-2007, 10:45 PM

Thanks Joe just doing what the site is all about. Sharing information.

**jackson** · 11-04-2007, 12:02 AM

thanks graywolf!!!!!!

nunk · 11-04-2007, 10:16 AM

very good tech info!!

**zukimudman** · 11-05-2007, 06:36 PM

on the starter fix are you jumping 30 to 87??

**GRAYWOLFGRAPHICS** · 11-05-2007, 08:49 PM

sorry no that just shows the path power is traveling.

**zukimudman** · 11-06-2007, 09:58 AM

ok thanks i have to make one today and i just wanted to make sure

**zukimudman** · 11-10-2007, 11:39 AM

i just got my relay and what not to fix my starter but the #'s don't match u pto yours this is what the side of the relay says

do i do it like yours and just fix the # or are your #'s correct

**scrubb** · 11-12-2007, 10:40 AM

87a is normaly closed. the above diagram shows what hapens when you apply 12V to the coil ( 85,86)

**zukimudman** · 11-12-2007, 10:47 AM

i talked to Graywolf on sat he helped me out and I got togo wheelin on sunday thanks for the help man.

and now that I know.. I now have 4 complet clicky fixes if any one needs one pm me

**GRAYWOLFGRAPHICS** · 11-12-2007, 11:15 AM

IM jelous. Ive had my sami torn apart so many time to mod this and that i havent driven it but about 10 miles.

**zukimudman** · 11-12-2007, 11:33 AM

now i just need to fix my leaky master .... my leaky exausht... get a lift and tires and get a new top and i'll be good

oregonboy · 03-06-2008, 11:36 PM

hey grey how would you use this with toggles im wiring illiterit(spell) and i suck at spelling!

Bass Man · 03-07-2008, 01:52 AM

On the relay, 86 would be your switch source, so you would run a fused constant 12v source to the toggle, then from your toggle, you would run it to your "86" on the relay.

If you remind me, I can show you how I wired mine so that you can't crank it unless the ignition is on.

Bass Man · 03-07-2008, 02:09 AM

Sorry to thread jack, but there is something I want to add, so everyone can determine the correct size fuse for your need.

Simple formula for converting watts to amps.
Usable Wattage / Power in Volts = Current in Amps.

So lets say for 2 simple 55 watt foglights:
2 x 55 = 110 usable watts.
110W / 14.4v = 8A

In this situation, you would only need to run a 10A fuse.

If you have 2 100 watt lights:
200W / 14.4v = 13.8A

Here, you would want to run a 15 amp fuse.

hedimitrius · 03-17-2008, 09:02 PM

Does anyone know if this clicky fix applies to an 89 kick 1.6L? I just had my Samurai start this $#!t.

**GRAYWOLFGRAPHICS** · 12-30-2008, 01:14 PM

As a side note to the above diagrams. I found a good source for the switched power. There is an unused switched power lead in the wire harness under the steering column. It goes into one side of the harness and isnt used on the other side of the plug. its red with a blue stripe and only has power when ign is in on or acc position. would be a good spot to connec your switch power. NOT the relay main power. Would assure your accessories are off when switch is off.

billsbar · 12-30-2008, 01:39 PM

funny timing, we were just looking at all the relays I have put under my hood
the list is
1 for KC lights
1 for fog lights
1 for electric fan
1 for electric fuel pump
1 for rock lights
1 for click fix
1 for alarm cut off
and I think I'm forgeting a few

**GRAYWOLFGRAPHICS** · 12-30-2008, 01:45 PM

see you can run the switch power to that wire i noted and it will turn everything off with the key

LiftedZuki · 03-07-2010, 12:37 AM

I got a question, I know this thread is old but very informative. If you run multiple relays, can you run a "terminal block" to power all the relays, and one bigger wire to the power?

11-03-2007, 03:32 PM	#1
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	clicky starter self fix and headlight relay OK i have seen the questions on here a million (maybe less) times. "Where do i get a clicky starter fix?" or "How i run a relay for my headlights or offroad lights?". This will be my first "how-to" here so be patient. 1, "WHAT IS A RELAY AND WHY USE IT" A relay is typically used to control a component that draws high amperage. The relay allows full power to the component without needing a switch or wiring that can carry the amperage. The switch only controls the relay. The relay then provides a direct connection to the battery. 2, "WHAT CAN A RELAY BE USED FOR" A relay can be used to control any component that draws high amperage. I personally have used relays for elect fans, starters, air horns and lights but the uses are about endless. 3, "HOW DO I CONTROL A RELAY" (pay close attention here and you will be amazed at how simple this is!!!!!) A relay can be switched by a positive or a negative source. (Yes i said negative source or "GROUND START" see note 5 below) A relay is simply a remote switch controlled by another switch. By applying power to a positive start relay you are simply telling the relay to close the switch within the relay. A ground start relay already has a positive source supplied and you are closing the circuit by supplying a ground (ie a thermostatically controlled fan or horn) 4, "WHAT THE ^%(& ARE ALL THESE CONNECTIONS" the power connection (86) and ground(85) connection in the relay (85) are the control or low amperage side. These are the ones that control the relay. (86) would be the one connected to the wire that you remove from the starter for the clicky fix* and (85) would be a chassis ground. When 12v is applied to the control side (86) it closes the switch or CONTROLLED side of the relay. The power SUPPLY connection (30) and switched power or load (87) connection in the relay. The power (30) connection should go to a fused power source with significant wire and fuse to carry the load of whatever you are trying to power. You can go straight to the battery with either an inline fuse or a fuseable link (not easy to replace on the trail). I suggest the inline fuse. The load (87) connection goes to whatever you are trying to power(ie CONNECTION WHERE YOU TOOK THE OTHER WIRE OFF THE STARTER FOR THE CLICKY FIX, lights, air horn, compressor, elect fan ect). 5, "WHAT IS A GROUND START CIRCUIT AND HOW DO I USE IT?" This is pretty simple also. As you know you need 2 things in a circuit. Power and ground. In a "GROUND START" circuit the power connection (86) will have constant power and ground(85) connection will go to you switch or control. For example: Wiring electric fans, (86) will have fused power preferably from a source that is powered with your ignition switch in the run position. (85) will go to a temperature switch in your block that grounds out at a set temperature. Supply (30) and load (87) will be as above. Keep in mind the load (87) will only supply the fans with power. You will still need to ground the other lead on the fan motor. 6, MOST IMPORTANT BASIC WIRING TIP This is pretty simple BUT OFTEN MISSED POINT. Do not run big wire as a lead to anything if you are going to skimp on the ground. A ground is just as important as the power supply (RUN THE SAME SIZE WIRE). Clean your grounding surface before attaching the ground and make a secure connection. 7, CAN I RUN HI AND LO BEAMS WITH A RELAY??? YES This is also pretty simple. as you noticed above we didn't use the powered off connection (87a). If you so desire you can run 2 relays with one sending power from its switched (87) to (30) on a second relay. The second relay would work as your hi-lo relay 7, CAN I RUN HI AND LO BEAMS AT THE SAME TIME WITH A RELAY??? YES This CAN BE DONE BUT NOT RECOMENDED WITH THE SAMI ALTERNATOR OR FOR BEGINNER WIRE NUTS. All you have to do is add a diode to the above circuit. Radioshack can supply you with the correct diode. A diode is easily understood like a one way swinging gate. if you have one this will be VERY clear. when you go out the gate it swings easily and out of your way, BUT when you are in a hurry and try to go the wrong way you end up with a face full of of wood or chainlink. A diode only allows power to go one way. LAST BUT NOT LEAST HERE IS WHAT EVERYONE HAS BEEN WAITING FOR THE "CLICKY STARTER FIX" GRAYWOLF GRAPHICS WILL NOT BE HALD RESPONSIBLE FOR AND DAMAGE DONE WHILE ATTEMPTING THE ABOVE HOW-TO. IT IS FOR INFORMATIONAL USE ONLY. PLEASE ENJOY THIS HOW-TO AS IT IS INTENDED FOR THOSE WHO LIKE TO SAY "I DID THAT" BUT IF YOU STILL FEEL SQUEEMISH ABOUT ATTEMPTING IT YOURSELF THE CLICKY FIX CAN BE BOUGHT FOR ABOUT $15 Last edited by GRAYWOLFGRAPHICS; 11-03-2007 at 04:33 PM.

11-03-2007, 08:03 PM	#2
johngat Join Date: Jun 2007 Location: Athens , Texas Posts: 694 Rep Power: 189	Nice write up __________________ 87 Sami , 3" Calmini lift with 2" longer shackels in the rear and Currie tow shackles in the front , Trail Tough Knuckle over steering , 1.6 8v swap , ZOR front bumper with Smittybuilt 8k winch and my most prized possession , ZOR full roof rack .

11-03-2007, 10:15 PM	#3
Itsmejoe231 Administrator Join Date: Jan 2006 Location: Highlands, Tx Posts: 102,209 Rep Power: 500	Nice!! I am going to move this in the FAQ section. __________________ ________________ _________________

11-04-2007, 12:02 AM	#5
jackson Join Date: Jan 2007 Location: arizona Posts: 8,081 Rep Power: 5743	thanks graywolf!!!!!! __________________ “ A well regulated Militia, being necessary to the security of a free State, the right of the people to keep and bear Arms, shall not be infringed. ” "The greatness of a nation and its moral progress can be judged by the way its animals are treated." Proud member of the bigflex padders union Local 10001 http://zuksoffroad.com

11-04-2007, 10:16 AM	#6
nunk Join Date: Jul 2007 Location: kc mo Posts: 158 Rep Power: 21	very good tech info!! __________________ NUNK www.myspace.com/heartandsoulcustompaint www.ZUKSofKC.us

11-03-2007, 10:45 PM	#4
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	Thanks Joe just doing what the site is all about. Sharing information.

11-05-2007, 06:36 PM	#7
zukimudman Join Date: Jul 2007 Location: West Hartford CT Posts: 538 Rep Power: 46	on the starter fix are you jumping 30 to 87?? __________________ if a deaf kid swears does his mom wash his hands with soap??

11-05-2007, 08:49 PM	#8
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	sorry no that just shows the path power is traveling. __________________ 87 rolled up ball of sheet metal from a careless driver who ran a stop sign. BUT, you cant keep the Wolfy down! pie R.I.P. Madhatter ________________ _________________

11-06-2007, 09:58 AM	#9
zukimudman Join Date: Jul 2007 Location: West Hartford CT Posts: 538 Rep Power: 46	ok thanks i have to make one today and i just wanted to make sure __________________ if a deaf kid swears does his mom wash his hands with soap??

11-10-2007, 11:39 AM	#10
zukimudman Join Date: Jul 2007 Location: West Hartford CT Posts: 538 Rep Power: 46	i just got my relay and what not to fix my starter but the #'s don't match u pto yours this is what the side of the relay says do i do it like yours and just fix the # or are your #'s correct __________________ if a deaf kid swears does his mom wash his hands with soap??

11-12-2007, 10:40 AM	#11
scrubb I'm a Toys R Us kid Join Date: Aug 2007 Location: Pleasant Grove AL. Posts: 4,503 Rep Power: 1266	87a is normaly closed. the above diagram shows what hapens when you apply 12V to the coil ( 85,86) __________________ 88 Sammy- weekend toy 92 Prelude- prodject for the wife 71 ThunderBird Shawnee- money pit 07 Grand Vitara Xsport

11-12-2007, 10:47 AM	#12
zukimudman Join Date: Jul 2007 Location: West Hartford CT Posts: 538 Rep Power: 46	i talked to Graywolf on sat he helped me out and I got togo wheelin on sunday thanks for the help man. and now that I know.. I now have 4 complet clicky fixes if any one needs one pm me __________________ if a deaf kid swears does his mom wash his hands with soap??

11-12-2007, 11:15 AM	#13
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	IM jelous. Ive had my sami torn apart so many time to mod this and that i havent driven it but about 10 miles. __________________ 87 rolled up ball of sheet metal from a careless driver who ran a stop sign. BUT, you cant keep the Wolfy down! pie R.I.P. Madhatter ________________ _________________

11-12-2007, 11:33 AM	#14
zukimudman Join Date: Jul 2007 Location: West Hartford CT Posts: 538 Rep Power: 46	now i just need to fix my leaky master .... my leaky exausht... get a lift and tires and get a new top and i'll be good __________________ if a deaf kid swears does his mom wash his hands with soap??

03-06-2008, 11:36 PM	#15
oregonboy Join Date: Aug 2007 Location: oregon Posts: 850 Rep Power: 394	hey grey how would you use this with toggles im wiring illiterit(spell) and i suck at spelling! __________________

03-07-2008, 01:52 AM	#16
Bass Man Join Date: Jan 2007 Location: Southern Oregon Posts: 5,680 Rep Power: 4755	On the relay, 86 would be your switch source, so you would run a fused constant 12v source to the toggle, then from your toggle, you would run it to your "86" on the relay. If you remind me, I can show you how I wired mine so that you can't crank it unless the ignition is on. __________________ Krooked 2 is SAS. And now its got a tube front clip! Help guide to building a durable budget Samurai My Dad's Shackle Reversal Build My 88 Sammy Semi-bug Get your own "Vote" Banner.

03-07-2008, 02:09 AM	#17
Bass Man Join Date: Jan 2007 Location: Southern Oregon Posts: 5,680 Rep Power: 4755	Sorry to thread jack, but there is something I want to add, so everyone can determine the correct size fuse for your need. Simple formula for converting watts to amps. Usable Wattage / Power in Volts = Current in Amps. So lets say for 2 simple 55 watt foglights: 2 x 55 = 110 usable watts. 110W / 14.4v = 8A In this situation, you would only need to run a 10A fuse. If you have 2 100 watt lights: 200W / 14.4v = 13.8A Here, you would want to run a 15 amp fuse. __________________ Krooked 2 is SAS. And now its got a tube front clip! Help guide to building a durable budget Samurai My Dad's Shackle Reversal Build My 88 Sammy Semi-bug Get your own "Vote" Banner.

03-17-2008, 09:02 PM	#18
hedimitrius Join Date: Mar 2008 Location: belleville, il Posts: 18 Rep Power: 0	Does this apply? Does anyone know if this clicky fix applies to an 89 kick 1.6L? I just had my Samurai start this $#!t. __________________ Anytime I see something screech across a room and latch onto someone's neck, and the guy screams and tries to get it off, I have to laugh, because what is that thing?

12-30-2008, 01:14 PM	#19
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	As a side note to the above diagrams. I found a good source for the switched power. There is an unused switched power lead in the wire harness under the steering column. It goes into one side of the harness and isnt used on the other side of the plug. its red with a blue stripe and only has power when ign is in on or acc position. would be a good spot to connec your switch power. NOT the relay main power. Would assure your accessories are off when switch is off. __________________ 87 rolled up ball of sheet metal from a careless driver who ran a stop sign. BUT, you cant keep the Wolfy down! pie R.I.P. Madhatter ________________ _________________

12-30-2008, 01:39 PM	#20
billsbar Join Date: Dec 2006 Location: colorado Posts: 11,799 Rep Power: 12805	funny timing, we were just looking at all the relays I have put under my hood the list is 1 for KC lights 1 for fog lights 1 for electric fan 1 for electric fuel pump 1 for rock lights 1 for click fix 1 for alarm cut off and I think I'm forgeting a few __________________ "Freedom is never more than one generation away from extinction. We didn't pass it to our children in the bloodstream. It must be fought for, protected, and handed on for them to do the same, or one day we will spend our sunset years telling our children and our children's children what it was once like in the United States where men were free." - President Ronald Reagan http://www.youtube.com/watch?v=pKFKG...layer_embedded http://www.youtube.com/watch?v=xxDwBYjL3Fc

12-30-2008, 01:45 PM	#21
GRAYWOLFGRAPHICS Join Date: Jul 2007 Location: Pahrump, Nevada Posts: 1,766 Rep Power: 3583	see you can run the switch power to that wire i noted and it will turn everything off with the key __________________ 87 rolled up ball of sheet metal from a careless driver who ran a stop sign. BUT, you cant keep the Wolfy down! pie R.I.P. Madhatter ________________ _________________

03-07-2010, 12:37 AM	#22
LiftedZuki Join Date: Oct 2008 Location: TriCities, WA Posts: 1,848 Rep Power: 6608	I got a question, I know this thread is old but very informative. If you run multiple relays, can you run a "terminal block" to power all the relays, and one bigger wire to the power? __________________ 87' Zuk as of 8/11/09! Sky stage 1, YJ SPOA, Locker & Spool, 5:1s, Snatch, Crab, 1.5" wheel spacers sitting on 33x12.50r15" Trxus m/t's/15x8 steelies.

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