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Offline Coldstone

Melted starter relay/solenoid
« on: August 17, 2022, 03:44:57 PM »
Has anyone had to deal with this?

Was not a nice surprise while out riding... and BAM dead machine and the lovely smell of melted plastic.

Good news is that I can replace the relay/solenoid on the easy, but the connector looks to be in a tough place. (Ideas / tips would be appreciated)

2019 800xc

Thanks

J
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Offline doug80638

Re: Melted starter relay/solenoid
« Reply #1 on: August 17, 2022, 06:11:26 PM »
Interesting design combining trigger, signal, fuse, and solenoid all in one unit.

The good news is they only cost $15.

The bad news is that these components should only carry a current for a few moments while the ignition switch in the starter position (if I understand the design correctly). If that is the case, what caused all the current, after the ignition switch released the starter circuit,  that generated enough heat to wreck things?

Faulty ignition switch perhaps? Stuck relay? Electrical short?

Or is it too close to something hot like the exhaust?
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Offline NMKawierider

Re: Melted starter relay/solenoid
« Reply #2 on: August 17, 2022, 07:10:44 PM »
From the looks of things it been in water and mud a bit. Maybe it got water in it...after all..nothing's water proof on these. Still..like doug80638 says, doesn't explain how it happened just riding along while running.
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Offline Coldstone

Re: Melted starter relay/solenoid
« Reply #3 on: August 17, 2022, 08:22:57 PM »
This bit is up front under the "hood" next to the battery, so nothing like exhaust temps near it.

I can't seem to find it right now my but I thought the 30A fuse (or what's left of it) was the fuseable link that sits between the rectifier/regulator and the battery?

It's def seen mud and water it's not never been in anything much past the foot wells, I wouldn't think it would do something like that, I could however be wrong.

I just hope I can clear out the connector... Or a new relay/solenoid/fuse isn't going to mean snot.

J
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Offline Coldstone

Re: Melted starter relay/solenoid
« Reply #4 on: September 10, 2022, 04:22:19 PM »
Ended up getting it apart, the culprit ended up being the fuse was jammed in and one of the terminals bent up and out so only a corner was touching, and it turn got hot and melted everything around it...

The replacement was cheap and made sure the fused was properly inserted and added a touch of DeoxIT to the connectors.

Let's see how long it lasts...

J
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