Relay assembly

[jyrki]

Hi, I had starting problem and bought new circuit cut off relay. When I move staring circuit cut off relay by hand, it makes clicking in certain positions, sometimes many quick clicks, so I suppose relay is ok? but there is some connection failure? Bike is not starting from start switch but if I ground starter relay Blue wiŕe, crank is rotating. Circuit cut of relay connector loose/defect? New cut off relay broken?

[Pat Conlon]

Starter button sticks (very common)
1st: Did you check the function of the starter button? Open up the switch and clean the contacts.
2nd: You could have a short or ground fault on the starter switch circuit (from the starter button to the relay) A chafed wire grounding to the frame could cause this.
Unless routed properly, the wires coming off the handlebar switches are subject to rubbing on the frame causing the insulation to wear thin and thus a short.

[red]

Hi, I had starting problem and bought new circuit cut off relay. When I move staring circuit cut off relay by hand, it makes clicking in certain positions, sometimes many quick clicks, so I suppose relay is ok? but there is some connection failure? Bike is not starting from start switch but if I ground starter relay Blue wiŕe, crank is rotating. Circuit cut of relay connector loose/defect? New cut off relay broken?

jyrki,

It sounds like the relay is good, but the bike wiring may be the problem..  Remove the relay from its' socket.  If you have a test light, find two new bare (not insulated) terminal blades, that are the same size as the relay blade connectors.  The new bare terminals should fit firmly into each position of the relay socket.  If any socket positions are loose, that could be the problem, right there (you may need a new relay socket, or need to repair the old one).  Ground one of the test light leads.  Check the coil wiring layout on the relay, or probe with the other test light lead to find the position in the relay socket that feeds voltage to the relay coil.  You may need to use the starter switch to make the coil voltage wiring turn on.  Insert a bare blade terminal into that position in the relay socket.  Use a wire with alligator clips to connect the other test light lead to the bare terminal.  Try your starter switch again, if needed, and see if the test light is getting solid voltage when you move the relay socket and wiring harness.  If so, you have good voltage coming to the relay. 

Now, check the ground line to the relay.  Insert another bare blade terminal to the relay coil's ground line in the relay socket.  Connect the test light's ground lead to the second bare terminal, and try the starter switch again.  The starter switch should turn on the test light, then.  Move the relay socket around, and make sure that all of the relay's wiring is good, not shorted or broken someplace.  Try the starter switch several times, and make sure it turns on the test light reliably.  Move the wiring harness also, looking for any fault. 

If anything there fails these simple tests, just find and fix the problem.  Since you have the starter relay removed, the starter will not engage during these tests. 

If your headlights are on while testing, you may want to connect a battery charger to the battery while testing.

HTH.

Happy hunting . . .

[jyrki]

Many thanks Red and Pat! Good to hear that new relay is at least ok... I need to get some terminals blades:)

[jyrki]

Found the reason! It was simply the relay socket...female connector, I just bent female connector blades to get prober connection. It was not only one connection.. many thanks for your help! Now I at least learned how my bikes electrics works,at least patr of it...

[red]

Found the reason! It was simply the relay socket...female connector, I just bent female connector blades to get prober connection. It was not only one connection.. many thanks for your help! Now I at least learned how my bikes electrics works,at least patr of it...

jyrki,
Happy to help.    When I need FJ advice, this forum is where I check first.

[aviationfred]

To help with conductivity for the connectors. I put a small amount of dielectric grease on each terminal before I put the connectors together. It helps to displace moisture and minimize corrosion.



Fred