Help. Starter Relay.

[asifnyc]

I *think* my starter relay is dead.  The battery is fully charged but the starter won't engage.  If I  short the relay terminals with a screwdriver the starter engages.  I did a continuity check on the OFF/RUN and START switches and they check out.

Where can I buy a replacement relay?

[Kerry]

There should be some more electrical tests you could do before you go shopping.  I can't locate my shop manuals at the moment, so I can't follow along with the drawing on Bike Bandit (under Electrical for the 1993 GS500E).

Do you know which internal relay circuit you shorted with the screwdriver?  Was it the low-current coil circuit or the high current switch that connects to the starter motor?

If it was the coil circuit, then you have continuity all the way to the relay from the various switches, etc.  That means the coil circuit is bad, and replacing the relay is in order.

If it was the switch circuit, then there are still 2 possibilities:  1) You're not getting power to the coil circuit, so the switch isn't being closed, or 2) The switch circuit is defective.

Let's go down path #1.  Do you hear any kind of a click when you press the starter button?  If so, then the coil circuit is probably functioning.  But I'm not sure whether this particular relay makes any noise at all.  The sure-fire test is to hook up an ammeter between the START switch and the coil circuit, and check for current when you press the button.  What I'm hoping is that a wire or connection needs to be replaced or cleaned up.

If the coil circuit checks out, then there is a problem within the switch circuit, and a new relay is probably your solution.

Disclaimer: This all came out of my general knowledge about how relays work, and NOT from direct experience with the starter motor relay on the GS500.  I hope I've been of some help, but take what I've said with a grain of salt.

[asifnyc]

I shorted the high current relay terminals (that have the heavy gauge black and red wires attached).  As I said, this engaged the starter motor.

When I press the start button the relay does NOT click.  I had the right hand side switch box open and checked that the OFF/RUN and START switches are working (continuity check).  So, it's either the relay itself, or the wiring from the switches to the relay.

The service manual says to disconnect the black cable from the relay, press the start button and check for continuity across the high current relay terminals. I did this and there was no continuity...
The manual mentions that you should hear the relay click. As I said, I don't hear the relay click.

I will try to check for continuity in the coil circuit.  Thanks for the info.  Btw, I can order the relay from Bike Bandit for $53.00... Man that's expensive.  Any idea why a relay costs so much?  Is there a cheaper option for parts?

Thanks again!

[JamesG]

There are some even more basic checks you need to do first.  Are you sure that the clutch lever and side stand/neutral interlocks are either functional or bypassed?

Either of those being bad will cause your problem.

[Greg Gabis]

I have had problems with my starter relay. It is expensive because it includes the relay itself as well as the main fuse (included) holder and spare fuse (included) with rubber housing. Kinda like three parts in one.

Anyway, you can by-pass the clutch switch inside the headlight bucket. It is the yellow with green wire.  Unplug the wires that run out to the switch on the bar and plug the now free ends into each other. Thanks to Bob Broussard for that tip.

If the bike is in neutral, the sidestand switch shouldn't have an effect on the starter circuit. I believe the neutral diode "bypasses" the sidestand switch. I don't understand diodes to well, so that's just a guess.

I believe that I damaged my starter motor from excessive use (you don't want to know). When the bike would get hot and I tried to start it, the main fuse would blow. I'm pretty sure it was the motor drawing way too many amps (consistent with damaged starter motor) and blow the fuse.

With the help of some electrical type fellows, we tested switches and other things and isolated the problem back to the relay but after some trial and error, I figured it to be the starter motor after all. I've replaced the starter motor but haven't got other stuff finished to test everything out.

I happen to have an "extra" starter relay that should work. I'll sell it to you for 1/2 price. It's been used maybe four times.

[asifnyc]

I checked the sidestand switch and it seems to work...
The clutch lever switch has me confused.  A local motorcycle place service guy told me to check that to.  BUT, when the bike was working for me I never had to pull the clutch lever to start the bike.  I always park the bike in neutral.  Then when I go to start it, I put the switch to RUN, put on some choke and press start.

So, does my bike NOT have a clutch lever switch or is it that the clutch switch is bypassed when in neutral?  Thanks for all the responses.

[JamesG]

The pesky clutch switch was probably disabled by a PO, its a common mod.  I would check that, chances are the splice or what have you has come undone.

[asifnyc]

Where is the wiring for the clutch lever switch?  Also, the service manual doesn't mention needing to hold the clutch lever to start the bike (I don't think, I'll recheck tonight...).

[nsoccer3097]

if the wiring isn't attached to the clutch perch, it's probably behind/inside the headlight.

[Turkina]

asifnyc, you probably got one of those UK manuals
Just trace the wire coming from the little rectangular plate beneath your clutch lever into the headlight shell, connect the yellow/green wires and bypass it.
It may or may not be your problem... I sat there dumbfounded as to why my bike wasn't starting with any reliability for months (yes, months!) until I posted a couple days ago.  
http://www.gstwins.com/forum/viewtopic.php?t=3330

[asifnyc]

Thanks everyone for all the help.  The problem was the clutch lever switch and NOT the starter relay (glad I didn't order a starter relay last week... I was *this* close...).

I soldered the switch leeds at the lever side and it starts now...  thanks again!