I would suggest you familiarize yourself with the layout before tackling the job. I have labeled photos below.
It is suggested (jimc) that you first disconnect the ground wire to your battery as a safety precaution. He explained it, "The advice to disconnect the negative is just because you have very high-current, unfused connections to the battery positive exposed on that relay - you really, really don't want those to make even the slightest contact to frame. You will lose your clock/temp settings and trip mileages, but not the overall odometer reading."
The compartment to open and get to the fuse is the one behind the battery held by a single screw (see photo with screwdriver in this location).
The hidden fuse is well hidden inside the relay. You must take it apart to get to it. When you first look at the relay (right side, only one with a red part) you will see in the back of it a spare. I suggest removing that spare before you start. You will be pulling the relay out of its holder and doing several things with it and you don't want to hurt the spare.
The relay is covered with a black rubber cover. The relay is held in place by two plastic fins which create its holder. The rubber has two slots which the fins slide through. You remove the relay from the holder by sliding the relay to the left, towards the center of the bike. (Jimc suggested sliding it forward. The 250 and 400 might slide forward. I am not sure, but the 500 relay slides out sideways. I think Jimc misremembered.)
There is a picture below of the back of the relay. In this position we can see that there are two red clips, one on each side, that must be opened to slide the red clip apart from the relay. Do not pry these open. Press them together at the back and the front will open - like two seesaws. Then slide the red clip out. This was VERY difficult for me to do but finally I got it. I had to use some long handled pliers. Be careful.
There is a picture of the relay open and the fuse exposed. Remove the fuse and use the dielectric grease on all the connections, including the group next to the fuse. At least that is what I did. Then put it all back together. Good luck. If you have a question, post it and I'll try to answer.
Relay separated - Hidden Fuse is green
Backside of the relay - squeeze back end of red clips to open
Parts of the relay
Area under seat to open (behind battery)
Last edited by jerryw on Tue, 30 Mar 2010 11:49:39 +0000; edited 7 times