Lever Action Solenoid
Seasoned HDF Member
Joined: Mar 2010
Posts: 21,117
Likes: 7,643
From: Poolville
Looks like in the one picture that you have 2 yellow wires going to the Solenoid... Don't think thats right...
Terminals 85,86 should be the coil in the relay and 30,87 should be the contacts of the relay that energize the coil on the solenoid pulling in the contacts on the solenoid and applying power to the starter motor.. So you will need ignition power to 12v, to terminal 85 and direct battery 12v to terminal 30.... The biggest problem if the contacts on the Bosch relay weld close (which they can) it will supply constant power to the Solenoid which will make the starter run on and then you'll have to disconnect the battery to stop it. So I would make both terminals on the Bosch relay a switched power supply off the ignition switch or some kind of manual disconnect.. Thats the way I see this diagram... Good luck...
Terminals 85,86 should be the coil in the relay and 30,87 should be the contacts of the relay that energize the coil on the solenoid pulling in the contacts on the solenoid and applying power to the starter motor.. So you will need ignition power to 12v, to terminal 85 and direct battery 12v to terminal 30.... The biggest problem if the contacts on the Bosch relay weld close (which they can) it will supply constant power to the Solenoid which will make the starter run on and then you'll have to disconnect the battery to stop it. So I would make both terminals on the Bosch relay a switched power supply off the ignition switch or some kind of manual disconnect.. Thats the way I see this diagram... Good luck...
Last edited by 98hotrodfatboy; Nov 13, 2018 at 06:04 AM.
Road Warrior
Joined: Dec 2007
Posts: 1,286
Likes: 64
From: SoCal
Looks to me that you have it wired correctly as it matches the schematic from the manufacturer.
It was mentioned but I don't think you responded to it, the metal plate the large Ford type relay is mounted on must be grounded.
The oil tank/battery tray are rubber mounted. They are not a good ground so bolting the Ford relay to the battery tray still doesn't connect to ground on the bike.
A wire from one of the bolts on the Ford relay metal plate to a good ground on the bike is necessary to complete the circuit for the coil (electromagnet) in the Ford relay.
Do you have that ground wire on the Ford relay metal plate?
Also, the small plastic relay in one of the kits I have installed was defective (blew two fuses before I isolated the problem).
If you need to replace the small plastic relay, get a 40 or 50 amp one to make sure it's heavy enough for the current flow required by the Ford relay.
It was mentioned but I don't think you responded to it, the metal plate the large Ford type relay is mounted on must be grounded.
The oil tank/battery tray are rubber mounted. They are not a good ground so bolting the Ford relay to the battery tray still doesn't connect to ground on the bike.
A wire from one of the bolts on the Ford relay metal plate to a good ground on the bike is necessary to complete the circuit for the coil (electromagnet) in the Ford relay.
Do you have that ground wire on the Ford relay metal plate?
Also, the small plastic relay in one of the kits I have installed was defective (blew two fuses before I isolated the problem).
If you need to replace the small plastic relay, get a 40 or 50 amp one to make sure it's heavy enough for the current flow required by the Ford relay.
Last edited by megawatt; Nov 13, 2018 at 09:00 AM.
Thread Starter
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Novice
Joined: Jun 2018
Posts: 15
Likes: 0
From: Wyoming
Looks to me that you have it wired correctly as it matches the schematic from the manufacturer.
It was mentioned but I don't think you responded to it, the metal plate the large Ford type relay is mounted on must be grounded.
The oil tank/battery tray are rubber mounted. They are not a good ground so bolting the Ford relay to the battery tray still doesn't connect to ground on the bike.
A wire from one of the bolts on the Ford relay metal plate to a good ground on the bike is necessary to complete the circuit for the coil (electromagnet) in the Ford relay.
Do you have that ground wire on the Ford relay metal plate?
Also, the small plastic relay in one of the kits I have installed was defective (blew two fuses before I isolated the problem).
If you need to replace the small plastic relay, get a 40 or 50 amp one to make sure it's heavy enough for the current flow required by the Ford relay.
It was mentioned but I don't think you responded to it, the metal plate the large Ford type relay is mounted on must be grounded.
The oil tank/battery tray are rubber mounted. They are not a good ground so bolting the Ford relay to the battery tray still doesn't connect to ground on the bike.
A wire from one of the bolts on the Ford relay metal plate to a good ground on the bike is necessary to complete the circuit for the coil (electromagnet) in the Ford relay.
Do you have that ground wire on the Ford relay metal plate?
Also, the small plastic relay in one of the kits I have installed was defective (blew two fuses before I isolated the problem).
If you need to replace the small plastic relay, get a 40 or 50 amp one to make sure it's heavy enough for the current flow required by the Ford relay.
Thread Starter
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Novice
Joined: Jun 2018
Posts: 15
Likes: 0
From: Wyoming
I ran a 10 gauge ground to where my negative battery cable is grounded, that made no difference, the relay just clicks still. I'm thinking the relay biffed. I have ordered a 40 amp relay. Hopefully
that will do the trick. Thanks for the advice, if anyone thinks of anything I might have missed please pass it on, obviously my wiring experience is lacking greatly
that will do the trick. Thanks for the advice, if anyone thinks of anything I might have missed please pass it on, obviously my wiring experience is lacking greatly
Road Warrior
Joined: Dec 2007
Posts: 1,286
Likes: 64
From: SoCal
A couple more things:
Which relay is clicking?
The small one or the big Ford relay?
Is the wire from the 87 terminal on the small relay connected to the "S" terminal on the large Ford relay?
As I recall, "S" terminal is the one for the coil (electromagnet) in the large Ford relay. The other smaller terminal sometimes is marked "I" and is not used.
You can test that by jumpering from the positive battery terminal to that "S" terminal.
Be aware if your battery starter cables are hooked up to the Ford relay the starter motor will energize (run).
Which relay is clicking?
The small one or the big Ford relay?
Is the wire from the 87 terminal on the small relay connected to the "S" terminal on the large Ford relay?
As I recall, "S" terminal is the one for the coil (electromagnet) in the large Ford relay. The other smaller terminal sometimes is marked "I" and is not used.
You can test that by jumpering from the positive battery terminal to that "S" terminal.
Be aware if your battery starter cables are hooked up to the Ford relay the starter motor will energize (run).
Last edited by megawatt; Nov 13, 2018 at 08:27 PM.
Thread Starter
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Novice
Joined: Jun 2018
Posts: 15
Likes: 0
From: Wyoming
It is the small relay clicking. And yes the 87 is connected to the S terminal. I took your advice and ordered a 40 amp relay.. I've re-traced that wiring alot and I'm fairly
certain everything is where it should be.
certain everything is where it should be.
Road Warrior
Joined: Dec 2007
Posts: 1,286
Likes: 64
From: SoCal
Well I sure hope it is the little relay that is the problem.
Do you have a volt/ohm meter to check for voltage on the 87 terminal when you are trying to start the bike?
Kinda too late now since you ordered a relay already.
Standing by for the result...
Do you have a volt/ohm meter to check for voltage on the 87 terminal when you are trying to start the bike?
Kinda too late now since you ordered a relay already.
Standing by for the result...
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