Brief run-in with Murphy today

[Fudd]

I went to leave a Patriot Guard mission this evening in pouring rain and I didn't have ANY electrical power.  I wiggled the wires on the starter relay and the power came back.  It started, and I left for home.  Two miles from home, still in the rain, but now dark, I lose all electrical power and the bike dies.  I brake hard, turn in a driveway and "poof," the power is back, it starts and I'm home.

Before anybody suggests for me to check the starter switch, it's not that.  TOTAL electrical failure, not just headlight and starter function.

I'm about to go see about a loose connection now.  I'm also going to look at the wiring diagram to see where or what around the starter relay can be giving me an open connection. 

Ideas appreciated.

[Fudd]

Well, that was easy enough to find.  The red plug on top of the starter relay had melted.   There was a poor connection at a loose blade connector.  The insulation was burnt off the wire as well.  Hopefully the relay can hold up till I get another one.  But for tonite, I'll replace a few inches of wire and replace the blade connector.

[Fudd]

Here's what the top of the relay looked like.



Looked like it got kinda warm, huh.

[RonW]

That red wire is a main artery OUT, and the defect will stop you smack dab in the middle of a highway if vibration disconnects it. Fortunately, Valk engines run smooth. The red wire came off at the crimp on my other bike's relay and ruined a battery before I stumbled upon it. Do you think that on a Valk, it's caused by the rubber boot not being large enough to fully cover up the starter-relay unit? Water eventually seeps in?

[Fudd]

Do you think that on a Valk, it's caused by the rubber boot not being large enough to fully cover up the starter-relay unit? Water eventually seeps in?

Well, if the rubber boot wasn't big enough before, it sure ain't now- with a big hole burned in it.

I'm going to check with the junk yard to see if they'll sell me a plug with 3 or 4 inches of wire that I can splice in.  I'll get another relay, too.  This one has been "thermally compromised."

[sandy]

After reading a few of these posts n the past, I cleaned all the contacts on the relay and coated them with a dielectric grease. 121K miles and no problems (YET).

[R J]

Here's what the top of the relay looked like.



Looked like it got kinda warm, huh.

At this link you will find a replacement connector that will work on the Valk.   I have one on mine.    Change the red wire to the empty plug, put on the new extra large rubber boot and good to go.

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

Find 'Starter Relay Repair' down towards the bottom on the right.

[Fudd]

At this link you will find a replacement connector that will work on the Valk.   I have one on mine.    Change the red wire to the empty plug, put on the new extra large rubber boot and good to go.

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

Find 'Starter Relay Repair' down towards the bottom on the right.

Thanks R J for the link, "you da man"

I'd seen this before but forgot about it.