HELP! Toasted Starter Relay and a Burnt Wire harnes

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by MY ADV, Mar 26, 2007.

  1. MY ADV

    MY ADV "ZERO.. POINT.. ZERO"

    Joined:
    Oct 20, 2005
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    585
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    Greshtucky, Orygun
    My 05.5 950 Adventure failed on me today. Only one day after I got it back from my dealer for it's 30K Mile service I found myself pushing it back home.

    The battery was dead and so I thought for sure it was bad. I bought a new battery and replaced it only to have it not power up. I wiggled and jiggled the connector on top of the starting relay and suddendly the power came on. The bike started but kept loosing electical power. I decided to remove the starter relay and found that the connector C_AE/4 was burnt and one of the pins on the relay was burnt off. My dealer tells me I need a new realy, about $70.00 u.s. and A new wire harnes about $475.00. :huh Who make this end connector and where can I get one?
    #1
  2. cagiva549

    cagiva549 whats a cagiva

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    Lets get this straight , worked good before going in for service , would not work after service and wiring harness melt down . I think I would be raising some hell , there is a 40 amp fuse to protect the main circut from melt down . I will look at my bike and see what the relay can be replaced with , Most relays of that style are in the $10 dollar and less price range . SEYA
    #2
  3. uk_mouse

    uk_mouse Aquatic adventurer

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    Those electrical connectors with the "concertina" style waterproof seal are made by AMP. They seem to be used very widely in the automotive world, although you might find that the particular model is exclusive to KTM, certainly BMW use some connectors you can't buy anywhere else.
    #3
  4. KTMMICK

    KTMMICK Adventurer

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    Seek the help of an auto elecrician, I am sure he'll be able to help, but first port of call should be to the dealer. At very least he should fit for free but probably should discount you on parts also.
    Let us know how you get on.
    #4
  5. slaw

    slaw not me gov!

    Joined:
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    :kboom :kboom :kboom over loading around the starting area is normally caused by trying to engage the starter when the battery hasn't got just enough juice to turn the engine.
    the fuse should of course blow!!!:kboom :kboom
    #5
  6. MY ADV

    MY ADV "ZERO.. POINT.. ZERO"

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    The fuse didn’t blow and that's what really pisses me off! :dog

    I dropped it off at the dealer this morning and now I hope that the dealer will work with KTM to give me a “Customer Courtesy” and get the thing repaired properly instead of just patching it with a new connector and butt splices.
    #6
  7. MY ADV

    MY ADV "ZERO.. POINT.. ZERO"

    Joined:
    Oct 20, 2005
    Oddometer:
    585
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    Greshtucky, Orygun
    Can anyone tell me who the manufacture is for the wire loom connector C_AE/4. This is the connector at the end of the wire loom that connects to the lower starter relay. I need to replace it and the starter relay. The starter relay is a Jideco Model MS5F-531, but I am not sure on the connector. Is it a Deutsch brand connector? UK Mouse said it was made by Amp / Tyco. If someone has found it please let me now.
    #7
  8. cpmodem

    cpmodem Orange Caveman

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    What part of the relay failed? Did the connector on the wire loom melt?
    #8
  9. keith_irl

    keith_irl Adventurer

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    I'm having the very same problem. I have solved it before by using mini spade connectors and pushing them straight into the relay. This is really only a short term fix as the connector you mention is only available from one source I know of. http://www.kojaycat.com/Motorcycle%20connector%204%20way.htm
    (Third one down) See pic 2.
    Unfortunately these are out of stock.
    The fix using the push on spade connectors really is only a temp fix as I have had two relays go to bits from this fix ax the pins on them just corrode when exposed to weather

    Sent from my Nexus S using Tapatalk
    #9
  10. 68deluxe

    68deluxe Long timer

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    40 Amp fuse??? I would think that is quite a bit to run thru the wiring harness.
    #10
  11. jamesbrown

    jamesbrown Lefty tighty.

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    It's a 30amp fuse.
    #11
  12. gefr

    gefr Life is a trip

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    I press the starter button and hear the starter relay arming but the starter doesn't turn. I open the skid plate and short the two thick wires, the white and the red and the starter spins in a spectacular sparking show and the motor is alive. Am I in need of new starter relay?:ear
    #12
  13. Peanuts

    Peanuts Long timer

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    The connector is available from any KTM dealer

    <TABLE style="WIDTH: 295pt; BORDER-COLLAPSE: collapse" border=0 cellSpacing=0 cellPadding=0 width=393><COLGROUP><COL style="WIDTH: 95pt; mso-width-source: userset; mso-width-alt: 4644" width=127><COL style="WIDTH: 200pt; mso-width-source: userset; mso-width-alt: 9728" width=266><TBODY><TR style="HEIGHT: 15pt" height=20><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 95pt; HEIGHT: 15pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" class=xl63 height=20 width=127> 000700000AE</TD><TD style="BORDER-BOTTOM: #f0f0f0; BORDER-LEFT: #f0f0f0; BACKGROUND-COLOR: transparent; WIDTH: 200pt; BORDER-TOP: #f0f0f0; BORDER-RIGHT: #f0f0f0" width=266>SPARE CONNECTOR AE 4-PINS</TD></TR></TBODY></TABLE>
    #13
  14. gefr

    gefr Life is a trip

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    The system is operational up to the relay clicking strongly. The contacts inside fail to connect?
    #14
  15. Joe Dirt

    Joe Dirt Been here awhile

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    I just went through similar symptoms and this information was extremely helpful in my troubleshooting. I turned the ignition switch and just heard a buzz or maybe an irregular fizzle (kind of hard to describe). The cluster did not illuminate and the starter button did nothing. The "event" that started this was just thumbing the starter one morning and what followed was an audible electrical pop and an apparent loss of electrical power. Those symptoms convinced me from the start that I'd blown a fuse. But to my surprise I couldn't find a blown fuse anywhere. Using my shade tree mechanic decision tree I moved to the starter relay and checking with a multimeter I could confirm that the relay was not energizing. I removed the relay and brought it in for a bench test. The schematic posted in this post was the only information I could find and proved to be extremely helpful. I decided to test for continuity across the power studs (multimeter in diode mode) and energize the relay by applying ground and 12V to pins 3 and 4. I got an audible click and an audible tone from the multimeter telling me that the relay was working. I repeated this about 25 times just to exercise the relay and there was no "sticking". I reassembled the bike and dug a little deeper......

    I keep a SAE connector connected to the positive lead and ground stud on the side of the bike. In all my investigation I'd simply checked battery power at my SAE connector and always gotten 13V. But when I opened the battery box it was immediately noticeable that the positive battery terminal had a patina of oxidation and sure enough the lead was loose to the touch. I recently installed at Shorai battery and shimmed the extra space with padding. This created some resistance to the resting position of the positive battery cable and I simply hadn't tightened the fastener enough. I cleaned the leads with light sand paper, electrical contact cleaner, and reassembled. VROOM! I'll go back with some dielectric grease to prevent further corossion after a trip to the store.
    #15