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Starter relay Mod

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Brian UK View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr 2018 at 07:54
Agreed, all those should be checked.

The most common from my experience is the battery not fully charged.
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iansoady View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote iansoady Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr 2018 at 10:25
I don't think the starter would take a very heavy current if it's not actually trying to spin the engine so would have thought 4mm cable would have been enough.

Agree with the other points though.

I rebuilt the (Valeo) motor on my V50 and it was a fairly straightforward job. I didn't need to replace the brushes though.
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Brian UK View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 14 Apr 2018 at 15:43
Agreed, running light it should spin ok provided the actual connections are reasonable.
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magwa View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote magwa Quote  Post ReplyReply Direct Link To This Post Posted: 16 Apr 2018 at 21:06
use a charged "jump starterpack" instead of the battery with the starter motor off the bike.
  The starter motor will spin quickly and easily  (in either direction )
you can check the solenoid throw the bendix cog out
 
Strip and clean all the old grease in the solenoid body.
Lube on reasembly with 3in1 oil not grease.
If all else fails you can always sell the bike.......I didDisapprove



Edited by magwa - 17 Apr 2018 at 11:56
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Bernyc View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Bernyc Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2018 at 13:43
Sorry for the delay, I have narrowed it down to the starter solenoid. I did the relay mod., but this still wont turn the starter motor, the starter turns  properly when I bridge the contacts though. I have separated the solenoid from the starter and tried to get that to operate, but nothing is happening with it. Just got to source one of them now and give it a go. Wish me luck.
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Mike H View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Mike H Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2018 at 15:32
OK then - sometimes it really is the starter motor is FUBAR Big smile


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Post Options Post Options   Thanks (1) Thanks(1)   Quote Ken-Guzzibear Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2018 at 20:41
they ought to be easy to get same as on many cars n bikes look on the part itself for the Bosch part number and search that...... you may be surprised what comes up
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Brian UK View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2018 at 21:06
When you tried to get the starter going using the solenoid, did you hear the clunk of it pulling in?
If not then the coils in it have expired, but if you did, either the pinion is sticking and not allowing full travel of the solenoid, so the plunger never reaches the contacts, or the contacts have got very dirty/pitted and no longer conduct.
 
Both of the latter points can be checked and resolved without resort to a new solenoid.
 
However replacement solenoids are available for Bosch starters as Ken said, do you know of a Bosch service agent near you?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bernyc Quote  Post ReplyReply Direct Link To This Post Posted: 17 Apr 2018 at 22:37
We are out and about tomorrow and I´ve googled bosche dealers, there is one on the way to where we are going, so I will call in there and see if they can test the whole thing. The problem is we are in Spain and my Spanish is not the best. Again I will let you all know how I get on.
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Brian UK View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 2018 at 13:54
Yes, language can be a barrier.

You need Manuel from Fawlty Towers there to help.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bernyc Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 2018 at 09:56
Right I´m getting fed up now, the starter and solenoid are working fine, had them tested, all ok. Back to the wiring for the relay, the orange/yellow which is the permanent live feed has a voltage drop of .02( this is the new run of cable from the battery), both the brown/white and the red/black which both get their power when the ignition is on also have a drop of.02, the yellow/orange which goes to the spade terminal at the starter has a drop of .01, yet still the bugger just clunks when the starter is prodded.
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Brian UK View Drop Down
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Brian UK Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 2018 at 10:38
Voltage "drops" like that are of no consequence unless there is a load on the circuit. What you need to be able to measure is the actual voltage at the spade terminal on the solenoid when you press the start button.
I suspect in your case it will be quite a bit lower than 12v. You should also check the actual battery voltage across the terminals under the same conditions, ie. when you press the start button. If this is also dropping considerably, then you may have a faulty battery.
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bernyc Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 2018 at 12:51
The battery voltage drops about half a volt when the button is pressed, The spade connector is not registering anything on the meter when the button is pressed, and yes  the connector is attached to the solenoid, I am getting the battery checked, should know in about an hour how that is. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bernyc Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 2018 at 16:04
The Battery has been tested and it is good, I found an older post on here where someone cleaned off the earth to the ecu and it cured his, tried that and still no good. I even tried running another cable from the relay to the starter solenoid therefore bypassing the ecu, but still the same problem, the only way the bike will start is by bridging the positive lead to the solenoid spade.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote johnno Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 2018 at 17:43
have you tried putting it in gear and rocking bike back and forth just in case starter is just sticking
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