The main relay is a common weak point for all late 80s/early 90s Honda vehicles, and the Legend is no exception. The symptoms are presented on
http://techauto.tripod.com/ and the solutions are
http://techauto.te.funpic.org/solutions.php. This is a DIY tailored specifically to Legend G1s.
When the main relay was originally assembled, too little solder was used on the circuit board, and after years of hot and cold cycles, the solder developed tiny cracks, resulting in a no-start situation because the fuel pump does not receive a signal turn on. The problem typically presents itself on very hot days, especially after the car has been recently run. This DIY shows how to repair the main relay in as little as 30 minutes. Even if your car has yet to show the symptoms, it is so easy to do, I would recommend it as a preventative measure.
Tools:
Phillips Screwdriver
Soldering Iron
Solder
1. First, remove the two
lower panel screws and disconnect all
four electrical connectors.
2. Remove the
two vent screws. The
main relay can now be seen by looking straight up around the location of the clutch pedal (this is even easier if you have an auto).
3. This is the main relay. Remove the
electrical connector. Next is the hardest part because of the location of the relay but is so much easier thanks to KAHRuzer's suggestion to remove the innards instead of the entire main relay itself. The innards are held in to the outer black case by two tabs. Press back the
unseen tab and pull down on the brown part of the main relay. Now do the same with the
other tab and pull the brown innards out of the case. This takes a little patience but is so much easier than finding a way to get to the screw that's on top of the main relay's black case.
4. These are the "innards" of the relay and the solder tools you'll need. If you look very closely, you'll see some minuscule cracks in the solder, especially around the connections that have very little solder to begin with (
http://techauto.te.funpic.org/images...ydryjoint.jpg). I have very little soldering experience (I just bought my first solder iron for this task... $13.99 at Home Depot) but this board was very easy to solder with a little patience. Simply add solder to all the connections that appear to need it (I added to 10-15 of the connections)
5. Here is the repaired relay. Installation is very simple and is the reverse of removal.
Let me know if you have any questions!
