harley starter relay problems

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

2001 YAMAHA TDM900 SERVICE MANUAL

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Filed Under (Yamaha) by admin on 20-11-2010

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CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch. -3- ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM -4- ELECTRIC STARTING SYSTEM ELEC 4 Main fuse 5 Battery 7 Starter relay 8 Starter motor 9 Main switch 12 Starting circuit cut-off relay 13 Sidestand switch 14 Neutral switch 49 Clutch switch 59 Engine stop switch 60 Start switch 61 Ignition fuse -5- ELECTRIC STARTING SYSTEM ELEC EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the side- stand is up (the sidestand switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the starter switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 4. Starting circuit cut-off relay Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) and battery (12 V) to the starting circuit cut-off relay terminals as shown. YES NO Replace the starting circuit cut-off relay. Does the starting circuit cut-off relay have continuity between blue/white and black? EAS00759 Continuity Tester positive probe sky blue Tester negative probe blue/yellow No conti- nuity 1 2 1 3 Tester positive probe sky blue Tester negative probe black/yellow Battery positive terminal red/black Battery negative terminal black/yellow 1 2 Tester positive prove blue/white Tester negative prove black 3 4 5. Starting circuit cut-off relay (diode) Disconnect the starting circuit cut-off relay from the wire harness. Connect the pocket tester (Ω 1) to the starting circuit cut-off relay terminals as shown. Measure the starting circuit cut-off relay for continuity as follows. Tester positive probe blue/green Tester negative probe blue/yellow 4 3 Tester positive probe black/yellow Tester negative probe sky blue 2 1 Tester positive probe blue/yellow Tester negative probe sky blue 3 1 Tester positive probe blue/yellow Tester negative probe blue/green 3 4 When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed. Are the testing readings correct? YES NO Replace the starting circuit cut-off relay. NOTE: EAS00760

Audio Oil Pressure Alert Relay Installation Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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Step 1) Wire Connection: Using 18-gauge automotive wire, connect the audio alert relay as shown in the Wiring Diagram – Figure 1. • Connect the supplied wire from #3 terminal on the audio alert relay to the oil pressure switch post. Note: The supplied wire is not reversible. The eyelet end must hook to the oil pressure switch. • Connect a wire from #2 terminal on the audio alert relay to the ignition switch post that receives power when the ignition switch is first turned on. • Connect a wire from #1 terminal on relay to the positive side of existing horn, or alternate sound device. • Note: The audio alert relay uses the oil pressure switch as its ground. On most motorcycles, this audio alert relay can be installed easily under the dash. Figure 1- Wiring Diagram Cot a Oil Pressure Switch Ignition Switch Audio Alert Relay 2 1 3 load Horn + + – Caution: Make sure all connections are insulated away from potential grounds. Do not disconnect any existing wire. Step 2) Testing : Turn ignition switch on and ensure oil pressure light is on. Leave ignition switch on. Wait 30 sec (T1) and ensure the audio alarm sounds for ½ second (T2). If the electrical test is successful, proceed to Step 3. If not, you may have to use a pezio alert in place of the horn. (Which is available at most Radio Shack stores.) If audio alert still doesn’t work, consult the wiring diagram and recheck all wiring connections. Verify timer set points have not been altered. If problems persist, contact us at (518) 884-9591. Step 3) Mount relay switch: Use standard zip ties (not provided) or similar means to mount the relay to dash mount post or dash base. Note: The timer relay can be mounted almost anywhere on the bike that will not be exposed to direct rain or weather

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

KTM Starter Gear Maintenance Instructions

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Filed Under (KTM) by admin on 26-11-2010

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Checking the electric starter motor for wear -Check Bendix 1 for smooth operation and signs of wear. -Check the sprocket of the electric starter for wear and radial clearance. -Replace O-ring 2 of the electric starter. -Replace gasket 3 . -Check starter idler gear 4 for smooth operation and wear, check that the bearing bushings are seated firmly. Electric starter motor – checking for and adjusting play -Mount the electric starter and the starter idler gear. -Mount the tighten cover 5 . -Move starter idler gear 4 back and forth in the direction of rotation, the maximum play may not exceed half the width of a tooth. -If play is larger, cover 5 must be removed and as many shims 6 with a thickness of 0.10 mm as necessary must be added to eliminate all play. Then remove one shim again. -Check the play again; the maximum play may not exceed more than half of the width of a tooth. 1 2 3 4 5 4 5 6

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