k75s starter relay

[analogman]

Apparently my starter relay is welded shut from trying to start the bike with a near dead battery.

Any recommendations on a source or tips for the replacement?

Scott

88 k75s

 

[pglaves]

Apparently my starter relay is welded shut from trying to start the bike with a near dead battery.

Any recommendations on a source or tips for the replacement?

Scott

88 k75s

Any dealer should have the relay. Be sure to fully charge the battery, or get a new one, before starting the bike with the new relay or you risk sticking the new one too.

It is in the box under the rear of the fuel tank, right rear corner with the two big wires.

 

[analogman]

OK, pulled the starter relay, is there a method I can use to test it?

I have continuity between the 2 small wire stabs but not on any other combination of the 4 stabs.

 

[pglaves]

OK, pulled the starter relay, is there a method I can use to test it?

I have continuity between the 2 small wire stabs but not on any other combination of the 4 stabs.

Just test for continuity from one big (bolt on) contact to the other big contact. If it is stuck you will see continuity.

 

[98lee]

The bolt on connections are the switched load (battery power to starter). The two small plug in connectors are the relay coil. When power is applied to these connectors, the load connection is made.

On a proper working relay, putting power across the plug in connectors will result in continuity across the bolt on connectors and removing the power opens the circuit across the bolt on connectors. If the circuit doesn't open, the contacts are welded together (caused by trying t o start with a low battery). If the circuit doesn't close when power is applied to the coil, the coil is bad.

 

[analogman]

So the small stabs are the coil that is energized when I press the start button.

Large stabs are the contact that is closed when the relay is energized.

Does the coil see 12v when energized or should I use some other voltage to check the contact?

 

[kioolt]

It uses 12v to energize the coil. Be careful, if it contains a suppressing diode internally across the coil (I believe it does, not sure) and you hook it up with the wrong polarity even for a split second it will blow the diode.

 

[98lee]

Based on the symbol on the relay and testing with a meter, I belive 0 332 002 161 starter relay uses a resistor for supression as opposed to a diode.

That being said, the CORRECT polarity for the coil is terminal 85 (the small terminal that is 90 degrees to the other three) for ground and terminal 86 for 12v+.

 

[analogman]

New battery arrived today, relay tested good, re-installed relay, installed new battery, bike fired right up.