anyone have a good reason why i should just wire in a high-current switch or a generic relay from radio shack instead of shelling out $50 for a new starter relay? anyone know how much current the starter draws?
dan
if you do your homework you can more then likly wire in another solanoid from a junk bike. should be able to pick one up for under 30$
A cautionary tale regarding this subject. A pal of mine once replaced the starter solenoid on his bike with a secondhand item from a different bike obtained from a breakers. When he attempted to start it the contacts were unable to carry the current the starter motor demanded. Result was that they welded shut, the starter motor and wiring overheated causing a lot of expensive damage. Fortunately he managed to disconnect the battery before the loom caught fire!!. The starter motor, solenoid and most the loom had to be replaced at great cost. Starter motors are designed to only operate for a few seconds and will quickly overheat, they draw a huge amount of current from the battery and will flatten it in less than a minute. Looking at the cross sectional area of the starter motor cable I would estimate a inrush in access of 100amps. Note also that the fuse does not protect the starter motor side of the circuit. My advice would be stick with the genuine OEM part from Suzuki.
if you really feel you need to rig it... adapt a 100 amp fuse into it... I believe toyota cars have a 100 amp main fuse, easily found at autozone/discount auto etc...