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01 F4i keeps blowing starter relays

Old 08-16-2018, 07:49 AM
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Default 01 F4i keeps blowing starter relays

I my F4i keeps blowing starter relays, 2 so far. Not sure the origins of the first starter relay, when it blew it i had to replace the plug from the wiring harness because it was melted so badly.
The 2nd starter relay was a cheapy from China (it came with the 15amp fuse, not sure why).

My mechanic thought it might be the regulator/rectifier but did a voltage test while the bike was running and was getting between 13.7 and 14.5 (no higher).
Note: Bike has been made into a stunt bike buy the previous owner with a few extra electronic bits... jet ski kill switch, speedo healer, fans on a switch.

Any insights would be appreciated


Last edited by donkeyf4i; 08-16-2018 at 07:55 AM.
Old 08-16-2018, 10:37 AM
74demon's Avatar
Administrator and MVN, March 2012/Oct 2013 ROTM
Join Date: Sep 2011
Location: socal 949/951
Posts: 7,684

Check your cable resistances, starter draw, and grounding points on the battery cable. Resistance causes heat. Everything in the circuit can take more heat than that little spot.
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