Author Topic: How the heck do I get to the electrical box to replace a starter relay  (Read 8169 times)

Offline DangerD1967

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 :dunno2: I am 90% certain I have a faulty starter relay...but have no idea as how to get to electrical box...removed seat and the module under it, trying to work towards the front to get to top of box, but it seems I might have to lift the tank, which I don't have a clue as how to do...please help this idiot who just wants to ride instead of paying someone all my "fun" gas money on what should be a simple repair.

Offline TimTyler

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How about including your name and bike model in your profile and signature?

You need to remove the seat then the tank.

If you have a fairing you'll need to remove some of that around the tank.

First disconnect the two fuel lines on the front left of the tank.

Disconnect the fuel pump power connector that's probably behind the right side-cover (behind where your right knee would be when riding).

Then remove the two clips securing the rear of the tank to the frame by sliding them backwards using small pliers.

Lift the rear of the tank about an inch then slide it backwards to remove.

Offline Bassv

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I don't think you have to remove the tank. Just remove the c-clips at the back of the tank, lift it up and stick a piece of wood under it. No need to remove any fairing also. Then you can open the relay box. Since the start relay is the one on the bottom right you may be able to get it out. No experience with that though...

K75RT 1991

Offline TimTyler

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Definitely disconnect the battery first if you're going to be sticking a wrench in the relay box without removing the tank.

Offline DangerD1967

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sorry, it is a 94 k75s...battery cable disconnected for certain since starter wants to run constantly even with key out and kill set to off...
Will try the clip suggestion.

Thanks and hope very people are reading; I'd rather be riding myself...

Dave

Offline TimTyler

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... since starter wants to run constantly even with key out and kill set to off...

Your relay is just stuck, probably because your battery is low.

Leave the starter relay installed and tap it a few times to try and un-stick it.

Charge your battery.

Reconnect the battery and see if it worked.

Offline JamesInCA

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You may even be able to dislodge the relay contacts without touching it directly. When mine occasionally does this I can get it to dislodge itself by giving a rather sharp rap on the right side of the relay box near the very back (closest to the seat). And I do mean a fairly sharp whack, perhaps with the back of a screwdriver.

The relay may or may not need to be replaced, even if you're successful in dislodging it this way (or by tapping on top of it directly, inside the relay box).

Lastly, this is often the result of a battery that needs to be replaced, not just charged. If you charge up your battery and this keeps happening, you might look to replacing the battery before the relay if the battery is old, or has been subject to periods of disuse, etc. Just because it tests at a good resting voltage doesn't mean it's able to deliver a healthy current to the starter. Sticky starter relay is one of the prime signs that it isn't.

Offline DangerD1967

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Howdy and thanks to all the posters and concerned citizens! An update: I was able to reach the electrical box with the gentle lifting of the rear of the tank(Yes battery disconnected) and one gentle tap to the starter relay stopped the starter wanting to engage. Of course one problem fixed and now onto next.....! :yow Now with battery reconnected, it won't display the gear nor light the green neutral indicator on the panel. The clock works, the ABS indicator blinks, I have turn signals and headlights, but bike will not start. I carefully removed the starter relay which revealed to be bright and shiny Inside and out. Carefully replaced, checked with gentle pressure all other relays. Put all back together....still no love. One side note; I did have the starter/turn cluster off the handlebars and cleaned contacts when I thought it was just a sticky starter button....Help Help Help

Offline DangerD1967

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 :clap: :bmwsmile The last part of my last post got me thinking...went out removed starter module cluster from bars, looked everything over, including the metal plate on the kill switch that has 3 dimples, even though it looked flush and proper, I had it 180 degrees wrong....YEE-HA! All lights on, she started right up, took her up and down the road through all gears, stopped shouted my thanks to the gods and headed back home....I now have a date with Natchez Trace Parkway this Saturday...I want to thank everyone now and for their future help!!!!!

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