Simple Question: Starter Relay (Answered)

Aside from the melty spot, that fourth slot is supposed to have something in it, correct?

As a background I took the bike ('04) off the trickle charger and the 30A main was blown. Just starting to dig in.

Hi Brian,

According to the wiring diagrams in the 2002+ service manual and in the 2005+ standard wiring diagram (coloured) there are only three small gauge wires into the starter relay module.

* Yellow/red - starter switch

* Green/red - clutch & side stand

* Red - ignition switch

My guess is that your overheated connector is the red power lead.

ps. keep the great photos coming

Lorne

Hi Brian,

According to the wiring diagrams in the 2002+ service manual and in the 2005+ standard wiring diagram (coloured) there are only three small gauge wires into the starter relay module.

* Yellow/red - starter switch

* Green/red - clutch & side stand

* Red - ignition switch

My guess is that your overheated connector is the red power lead.

ps. keep the great photos coming

Got it, thank you.

And yes will do, many more to post.

I have seen melting of this connector on more than one bike. Most common cause corrosion or conncetors loosen their clamping force. Transition resistance causing heat and melting the plastic connector. Remedy: remove corrosion and use a pincer to tighten the female connector.