Join Date: Mar 2012
Location: san diego, CA, USA
starter / electrical gremlins question
i've been dealing with some electrical gremlins and have a quick question.
i was having odd electrical issues with blinkers going bonkers, headlight going out sporadically, and occasional "buzz" when pushing starter button.
- the battery is under a year old
- I lived with it a few months b/c sometimes it would "fix itself" (turn bike off, restart), sometimes rocking bike back & forth in gear would remedy it, and sometimes tapping the starter relay would fix things. I'm honestly not sure which was a fix b/c if doing nothing could fix it you could be fooled by tapping or rocking
In any event, last week after losing all lights again while riding I took the starter out, replaced brushes and cleaned it up a bit. Put starter back in and everything seemed fine ..for a day.
Post op day #2 I get just the fuel pump buzz. I then removed starter relay, pried it open and lightly sanded the contacts, which looked pretty good at the time and were not fused together.
I replace starter relay but no luck. Still just a buzz when hitting starter. I also notice the headlight doesn't dim when pushing starter button.
I should mention I hear something clicking when pushing the start button. I feel it is the starter relay but am not certain.
I noticed my horn relay and shed relay have identical part #s. I swapped them hoping to find the problem and have a bike which starts but has no horn. That didn't work. Horn works with either relay in place.
Today I took a bit of a gamble after looking at the schematic. What I did was turn the key and jump the terminals of the starter relay. Voila, the bike fires right up. The headlight dimmed during the split second it took to start.
So my questions are:
Can I be sure the starter relay is the problem? It seems to be but I don't want to overlook anything and then fry a new one. I'm asking b/c I did change the brush plate and maybe something is wrong in that. However when jumping starter relay the starter seemed to work normally.
If I jump the relay to start the bike, is the bike now running normally? Will a bad starter relay create any potential disasters?
You can probably guess my final question.
Until I find a relay is it "crazy" to wire a heavy duty pushbutton between the starter relay terminals and use that button instead of the starter button?
thank you very much for any insight.
Sorry, I am an abject liar and this was not a quick question.
If anyone has a relay they'd like to sell, feel free to send me a message. I believe they are $65 at beemerboneyard but i'd pay $30+/- or so for a used one.