starter relay fuse holder melting

[brido]

hi all checked over connections and everything seems to be okay, nothing obvious except for the starter relay melting.
took it for a quick run around the block and it started to visibly melt more.

Have ordered a new starter relay of ebay and will try and fit it to the bike, but it looks as if I am going to have to butcher the old one to get the new one on, and I need a new block connector for the loom side if anyone knows of where I can get one that would be brilliant

[royster81]

I might have something on an old loom I have in the garage, pop up a picture of what you need and I'll look tonight.

[brido]

For future reference you can get the starter motor solenoid connector block from towzatronics on ebay http://www.ebay.co.uk/itm/290565229834? ... 3D1&_rdc=1

[Neosophist]

hi all checked over connections and everything seems to be okay, nothing obvious except for the starter relay melting.
took it for a quick run around the block and it started to visibly melt more.

Have ordered a new starter relay of ebay and will try and fit it to the bike, but it looks as if I am going to have to butcher the old one to get the new one on, and I need a new block connector for the loom side if anyone knows of where I can get one that would be brilliant

Did you clean up the fuse conections througly? and replace the fuse (could have bad connections)

Some fuses are slightly thinner.

A poor fitting fuse and / or corroded / dirty connections will cause more resistance.. this generates excessive heat as the current tries to overcome this.. then your plug melts.

This is why the yellow-wire plug from the alternator melts often.. it gets corrded up and the extra heat burns it up

[brido]

Hi neo wasn't able to clean any connections as the fuse holder had melted to the starter relay and until I was able to get a new connector block I wasn't going to try and break them apart, I have now got a block from a place called towzatronics on ebay. So when I get some time I will replace the lot and see what happens, hopefully this cures it.

[brido]

Okay update on the melting problem, I have got the starter relay replaced with a new one and a new connector block replaced onto the loom side of things, everything wired up, plugged in and running. Just need to take it for a run, so weather permitting next monday or tuesday. Will update on how things go.

[Chrissy_J]

For future reference you can get the starter motor solenoid connector block from towzatronics on ebay http://www.ebay.co.uk/itm/290565229834? ... 3D1&_rdc=1

Well how about that... I didn't know you could get these...
Saves on the cost of a new solenoid every time...