Main Relay Trouble

[MotoPsycho]

Ok, so my main relay got wet last week. Riding in heavy rain kind of wet. Went to start my bike a few days later and the battery was totally dead. After charging the battery back up, the main relay clicked but no headlight, dash. Anything other than the main fuse circuit was dead. I tested the relay with the meter and got no continuity on the brown wire that goes to the fuse block. I got a replacement relay at the auto parts store going off of the relay model number. On the stock one there are two 87 terminals and on the new one 87 and 87a. Is it possible the contacts of the new one are backwards and I can swap wires in the plug and fix it? Living in Hawaii I could order a part from Chris Kelley or somebody in Cali and pay as much in shipping as a small part like that costs to begin with.

[Howie]

The only difference is labeling  30 is battery voltage in, 87 is output, 85 is trigger and 86 is ground.  Both will be hot when the relay is energized.  Since the relay clicks one can reasonably assume 85 and 86 are good.  You can test the relay itself by applying battery+ to 85 and battery- 86 with an ohmmeter across 30 and 87.  The ohmmeter should read close to no resistance.  If the relay tests good then check the connector for power at terminal 30 and 85 with the key on.  Then check that 86, the ground is good.  No good?  You will need to trace back to find the problem.  Good?  With a jumper wire bridge from 30 to 87 and the bike should power up.  If not, there is a problem in that wire.

[MotoPsycho]

Thanks Howie. The old relay clicked telling me it is energized. The new one does not. The contact on the old one is visibly burned out. I'm assuming that's why the battery drained. I did already test continuity from the ignition switch to the relay and voltage is ok. The only thing I didn't have continuity on was the output (brown wire) to the fuse block.

I will test everything else out per your instructions tomorrow to see how far I can get.

[MotoPsycho]

I tested the old relay. Got .650 and slowly creeping up. Referenced the new relay and got 0. So the old relay seemed to be no good. I installed the new relay and and got nothing. So I put the old one back in to see if I got the click and now the damn thing works again. What's up with that?

[Howie]

Sounds like the new relay is defective.  The old one might be working now, But what about the future?  My guess are the contact points are dirty or bad.  Replace it with a name brand (like Bosch) relay.

[kokis]

Hm I have similar issue but with new gen monster.
Can't find problem.. everything seems fine but not works.

[MotoPsycho]

I found out what happened. I dropped the relay off at the shop I go to so they could track down the number for a replacement. Nobody told me they did the sandpaper trick on it. I'm getting a proper backup from a dealer soon. Just in case.

[Howie]

Good to hear.  Do get a new relay.  The ''sandpaper trick" often is temporary since the contact points are usually tungsten coated and once the tungsten coating wears off severe pitting follows.   

[SpikeC]

 Following the sandpaper with polishing paper will prolong the temporary fix.....

[kokis]

So he just had to clean contacts on main relay?

[MotoPsycho]

Yeah, come to find out that's what they did. I dropped it off so they could look up the numbers on it and picked it back up a couple of hours later. Once I thought about it, I called and asked if they messed with it and was told that. I hadn't tried it again after I picked it back up until after I voltage tested it in my previous post.

[SpikeC]

 unbelievable that they didn't tell you that up front......

[MotoPsycho]

Ordered a new relay today from Pro Italia. $27 shipped to Hawaii. I'll take it. While I was in town today to see what the deal was. The mechanic didn't say anything because he didn't get to test it by the time I got back to pick it up. I'm not complaining. He never thought it would work anyway because I showed the contacts looked burned out and he concured. It was a shot in the dark but it worked. Either way I have a new relay on the way and the one I have works for now. Thanks all once again for the help.