NEED HELP: Starter Solenoid - Super 8 125cc

[WIZ 46]

Hey guys, sorry if I am posting in the wrong section, but couldn't find the 125cc section. 

I am someone with only some basic knowledge of scooters and I have tried to find a direction as to my problem.

I have the basic instructions on how to test a starter relay for problems, but I do not have a voltage tester, nor the time or experience to disassemble the wiring to check for grounding problems.

My basic symptoms are: with key in ignition, lights will go on, but no crank on the starter, no clicking, absolutely no sounds. When I disconnect the 2 connectors on the starter relay and then reconnect again, ignition and engine will start and everything works fine. I have read in the service manual that when checking for starter relay problems, you are suppose to check the voltage between the connectors, and you should also check the grounding from the starter relay, both of which I do not want to do myself.

I was just wondering if the disconnecting and reconnecting of the starter relay connectors and its ability to start after that, gives anyone any good ideas as to what my problem is.

The reason I am asking is that I am in the Philippines and none of the Kymco servicing centers in my area carry a starter relay. I have to purchase one from a main supplier and have a local servicing center install it. I don't want to have to initially take the scooter to a local servicing center for testing due to the probable event of the vehicle not being able to restart once I am there. I would rather have the new starter relay in hand before bringing to servicing.

Appreciate any help or comments.

Thanks.

[tjupille]

It sounds like your starter relay is sticking. There is nothing special about that part. Any relay for a generic GY6 should work.

[Vivo]

Welcome, Why can't you ride your scoot to the service shop, you still can start your scooter with the kick start right?

Starter relay is available at Supremebike Center (Kymco Dealer), Marcos Highway near the old Sta. Lucia mall for 404.00 pesos... call 477-13-24 and look for Rodel... or you can go to Rizal Ave, Caloocan, and get a generic starter relay for a GY6.  Installation is usually free.

[WIZ 46]

Hey, thanks Tjupille.

I was just wondering what do you mean by the relay sticking? I mean what is actually going on? The reason that I am asking is that I would rather it be a faulty relay then a simple grounding problem. Then I wouldn't have to waste my money buying a new relay.

[Vivo]

Hey, thanks Tjupille.

I was just wondering what do you mean by the relay sticking? I mean what is actually going on? The reason that I am asking is that I would rather it be a faulty relay then a simple grounding problem. Then I wouldn't have to waste my money buying a new relay.

The relay switch has contacts inside. As the contact tips begin to wear they will start to show signs of arcing damage as the circuit current still wants to flow as the contacts begin to open when the relay coil is de-energized.  This arcing or sparking across the contacts will cause the contact resistance of the tips to increase further as the contact tips become damaged. If allowed to continue the contact tips may become so burnt and damaged to the point were they are physically closed but do not pass any or very little current.

[WIZ 46]

Hey VIVO, thanks for the info.

The thing is that the bike is brand new 2013. Problem started occurring about 4 months after I got the bike. The initial symptom was the relay continuing to run even with the ignition key out keeping the engine running, which I believe is the evidence that it is the relay. I would have to disconnect the relay to get the engine to shutdown.

But here's the weird thing. Today, I disconnected and reconnected the wires running from the battery to the relay. Nothing much was happening. Again, disconnected the wires from battery to relay, and then I just jiggled the wire running from the relay to the starter to make sure everything is tight and sitting properly, and then I reconnected the wires running from the battery to the relay. Now everything works fine. Will start with electric switch or by kick. No problems now. I just can't figure out what the real problem is. It has been working fine all day.

About 2 months ago, I had 2 technicians look at it. One guy said it was the grounding. He did what ever he did (I wasn't paying attention) and the bike worked for about 1 month. Then same problem occurred. 2nd guy said it was in the starter switch, which he disassembled and there was evidence of green acid build up and arcing, something similar to what would be on a battery terminal. He said that the connectors were out of place and the acid was helping to keep the flow of the circuit going which was causing the engine to not shutdown. So he cleaned the switch and everything was fine for about a month. Now same problem. But as you said, the best guess would be the relay itself. I just cannot figure out why it works now....humm.....

[tjupille]

Loose or corroded connections are certainly a possibility. As far as replacing the solenoid goes, they're cheap ($15) even in the US. Given the higher popularity of scooters in the Phillipines, it should be even less there.

[Vivo]

Come to think of it, Tjupille has a point... When my super 8 was new, I had problems with the ignition switch, fuse, battery, horn, etc... most are loose or corroded connection problems... wd40 and contact cleaners helped a lot...