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Author Topic: optional starter relay conversion  (Read 5526 times)
kruzn
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Posts: 65


Illinois


« on: July 26, 2012, 03:34:43 PM »

Well, the Lady in Red ('97 Red/White) finally left me stranded along the road with a fried starter relay and plug.



The dealer didn't have one in stock and to be honest, I wasn't too happy with the main 30A fuse being included in that relay assembly anyway.

So, I went to the auto parts store and picked up a heavy duty starter relay for 85-99 Ford (Wells #F492)and a heavy duty in-line fuse holder.

The Ford relay is grounded through the mounting bracket, so it must be insulated from the bike frame. I cut the original relay mounting ears off the battery/tool box, drilled two 1/4" holes and mounted the new relay to the plastic box (into the tool section, NOT battery box). Then connected the green/red wires to one of the mounting bolts with a ring terminal. This keeps the safety circuits operational.

The yellow wire (starter button) is connected to the "S" terminal of the new relay ("I" terminal is not used). Connect the positive battery cable to one of the large terminals and the starter cable to the other. This required soldering new ends on the cables.

I soldered the new in-line fuse holder (w/30A fuse) to the red wire (ign switch feed), then connected to the battery side of the relay.

I believe this is much safer set-up than original (which darn near burnt my bike up!) . The Ford relay will probably out-last the bike!

And...it cost less than $15.00!  cooldude New Honda replacement relay is $40+



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Cruisin Dave
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1997 Honda Valkyrie Tourer SE
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