Good Morning, hopefully somone can point me in right direction. My 863 G series keeps blowing the 5 pin starter relay (fuse panel is front of the seat). It will run fine for an entire day and the next day the relay is blown. When I replace the relay it will start and run fine, then blow it again. I followed the wiring harness and didn't find anything shorting. Can anyone tell me what could possibly be wrong.
863 G blowing starter relay.
- Thread starter Tater91
- Start date
Maybe test to see if the relay is somehow getting power when the machine is off or see if it is warm or hot after using the machine or when the machine has cooled down. Maybe the ignition is somehow sending power to the relay even when the machine is off.
Just some thoughts.
Depending on what end of the relay is failing.
You're best opening up a failed relay for diagnostics or testing continuity across pins for coil & contacts.
Melted relay base usually indicates poor pin contact. They heat, expand, corrode, wear & lose contact tension. Replace female connector into the back end of fuse panel. (They should be a tangless metripac 280 )
Burnt relay internal contacts would indicate the starter solenoid shorting or short between relay & starter solenoid.
Burnt relay coils would indicate a large array of possibilities. Voltage issues. Dead shorts. Constant power issues. Very unlikely in most cases as the coil itself is built to be literally powered "on" for days continuously.
Or as previously mentioned, possibly being partially powered which is unlikely as this would likely keep the starter engaged when engine is running.
You're best opening up a failed relay for diagnostics or testing continuity across pins for coil & contacts.
Melted relay base usually indicates poor pin contact. They heat, expand, corrode, wear & lose contact tension. Replace female connector into the back end of fuse panel. (They should be a tangless metripac 280 )
Burnt relay internal contacts would indicate the starter solenoid shorting or short between relay & starter solenoid.
Burnt relay coils would indicate a large array of possibilities. Voltage issues. Dead shorts. Constant power issues. Very unlikely in most cases as the coil itself is built to be literally powered "on" for days continuously.
Or as previously mentioned, possibly being partially powered which is unlikely as this would likely keep the starter engaged when engine is running.
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sunnyboy
Member
- Joined
- Jan 24, 2009
- Messages
- 21
Based on your description of the problem, you are getting a large amp power draw *sometimes* when you start the motor. The most likely cause of this would be INSIDE the starter, probably in the rotor windings. Each time the starter stops, the rotor will be in a different position from the last time. Occasionally it's in a position where the windings are drawing a lot of current, and this blows your relay.
The solution is to find a place that can diagnose/repair the starter. I had the exact same thing happen to mine, except it was so bad it actually melted one of the big power wires from battery to starter. Having a shop rebuild the started fixed the problem.
The solution is to find a place that can diagnose/repair the starter. I had the exact same thing happen to mine, except it was so bad it actually melted one of the big power wires from battery to starter. Having a shop rebuild the started fixed the problem.
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- May 11, 2011
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- 100
When you say relays blows; is it coil of relay or contacts of relay are ruined?
You can check coil of relay using a volt-ohm meter set to ohms. Coil should have same resistance (with in a few ohms) as coil of new relay. Coil which is burned up, could appear as a short (few ohms only) or open (hundreds of ohms).
Another way to check coil of blown relay is connecting coil leads (or pins) to 12v battery. Relay should click (hear or feel). Verifiable with volt-ohm meter by contacts showing closed / opened as 12v is applied / removed.
If the coil is being blown, couple of possibilities.
One is coil is getting to high a voltage, above 14v. By chance do you hook 863 up to a battery maintainer or charger overnight? Can you check voltage of running 863 G to make sure it's voltage regulator is working properly; not exceeding 14v (usually 13.6vdc).
Another possibility is coil of relay is getting voltage spike. Possibly from a failed diode / rectifier which prevents reverse power cycle (voltage spike) when relay's power is dropped and starter motor looses power.
If the contacts are what is being ruined, then I would check the starter motor's solenoid. Which is what actually connects start motor to main power lead(s) coming from battery. It could be starter motor's solenoid is partially shorted, drawing to much power. Another possibility is wire coming from relay going to starter motor's solenoid is partially shorting to ground. Not enough to prevent starter motor's solenoid from working, but enough to ruin contacts of relay.
DID YOU GET IT FIXED? IF SO WHAT WAS WRONG?
863 starter blowing did you get it fixed if so what was wrong
answer yes or no if the fix is shared then everyone who gave or read the info wasted their time
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Finally got it fixed, Blind luck. A power wire in one of the plugs was broken. It would make the connection sometimes and not other times. When Unhooking the plug to clean it again the wire just happened to pull out. I wired it direct around the plug in and now the ole gal fires right up. Crazy how after hours of trying to figure it out that it was just a broken wire hidden in the pulg in. My son in law and I were ready to give up when we found it.
