Starter relay repair

[Toledo Mark]

Bike won't start. Does nothing. No horn. No light.   Road to Ann Arbor to eat. Came back out bike won't do a thing. Checked kill switch. Starter button new. Found problem to be a fried starter relay connection.

[Toledo Mark]

I have a trailer coming. Turns out it is the connection at the starter relay where the red thing plugs into the green thing.  They appear to have been melted together. I will order parts when I get home. Any advice on changing them out would be appreciated. I figure I way have to order a new red connector and splice it into the wiring harness. Again any advice is appreciated.

On the red and green connectors it is the red wire I believe is the issue.  It is that corner that is melted.

[Patrick]

If I remember correctly, I think it was RJ that had a post regarding that some years ago, it even had pictures !

[R J]

Go to this link.

Almost to the bottom on the right side is starter relay repair.

http://www.jkozloski.com/generic_parts.htm

PS:   Get a relay on whatever addition you added in the electrical line.

[Toledo Mark]

RJ, thanks for the info.  I found the part number 35850-MT4-000 on Amazon for 10.50 and at Honda Direct Line for $70.

Which one would you purchase?

[Toledo Mark]

Pictures of relay

Another picture of the relay

Trailering it home about 60 miles

The last 6 miles were on this wheel. No spare.

[Toledo Mark]

So I ordered the parts listed on the link RJ posted and I would also like to thank Leon from Alabama for calling me.

Leon,  when I got home I discovered the battery in my multi-meter was dead.  I replaced it, tested the battery and it came in at 12.9 volts.

[Toledo Mark]

Should I use dielectric grease when reassembling?  Put right on the terminal?  Any advice is appreciated.  Thanks,  Mark

[Toledo Mark]

Don't think I will reuse this.  Parts are ordered. 

I have a Cobra Lightbar on the bike.  No relay, I wired it like the directions showed 14 years ago.  If I start the bike without the lights on is it fine until I get a relay installed?  Once bike is running turn them on? 

Because isn't the issue when being started?

Thanks, Mark

[R J]

RJ, thanks for the info.  I found the part number 35850-MT4-000 on Amazon for 10.50 and at Honda Direct Line for $70.

Which one would you purchase?

Honda Line $70, that can't be correct for the part.  I think I pai like $7 to $10 for it.



This is the part # ya want and all these pieces are in the bag.    You will have to move the RED wire in the new unit to match your bike.

[Toledo Mark]

I posted on the Valkyrie group in Facebook and someone suggested I connect the red wire to an inline fuse then run it to the top screw of the 55amp main fuse.  I would then leave the terminal on the relay for the red wire empty.

Has anyone done that?

[mmurffy03]

after I fixed a friends bike that this happened to by splicing wires I found this one on ebay that had both parts and looked better than the one I did

http://www.ebay.com/itm/Starter-Relay-Solenoid-MALE-CONNECTOR-PLUG-Honda-GL1500-VALKYRIE-1997-2003-/300818976813?pt=Motorcycles_Parts_Accessories&hash=item460a35502d&vxp=mtr

[Toledo Mark]

I was thinking you could almost leave the red plastic thing off and just slip the female terminals on couldn't you?  Then get a water tight seal?

[Bocephus]

I had the same problem last summer. Stopped to get fuel and that's all she wrote. Ordered relay from amazon for $10.50 free shipping ( ordered 2 ) and it was identical to factory. Worked perfect. Good luck.

[Rio Wil]

I wonder what Honda's rationale was for including the 30 main fuse circuit in this plug connector. That red wire goes to the ignition switch and carries current/voltage for the bike operation. By incorporating this circuit in this plug it creates an additional connection vs just running it to a fuse block and then to the ignition switch..... it is true there is a big honking bus connection at the relay to tap off of, but to run it through the red wire connector is just asking for trouble.

[Toledo Mark]

I plan on bypassing that when the parts come.  I am going to run the red wire to an inline 30a fuse then to the top screw of the 55a main fuse.

Unless someone can tell me that is wrong.

[Rio Wil]

Electrically, it is the same, but since you have the bus available at the relay, just attach your inline fuse to that screw(battery side of the relay).

[gordonv]

Didn't someone this year, maybe 3 months ago, post about a mod they did of adding an inline fuse, and not using the one on the relay? Anyone else recall, and the reasoning behind it?

[Toledo Mark]

Just want to make sure I am correct in what I am doing.

What you are looking at is the old relay with the wires cut.  I am waiting for the new relay and the red connector.  Should have them this week.  Under the black electric tape the two wires are soldered together.  When the new relay arrives I will connect the three wires to two of the terminals leaving the spot that had the red wire empty.  The end of the inline fuse runs to the top screw of the main fuse.

I am leaving the old relay attached so I can use it as a guide as to which wire goes where.

Do I have it right?

Thanks,  Mark