Key switch relay keeps blowing.....

[NashXb12R]

Hi, I have a 2004 Buell Firebolt Xb12R, one day I was riding and it stalled out, I managed to get it runnin again and got home it ran fine all the way home. I got in my driveway and shut it off, then turned the key to try and start again and the center light between neutral and the oil light was not lighting up and the fuel pump was not priming... So I took the relays out and noticed the one on the top left which is the key switch relay i believe had a melted prong in the center so I went a bought a new one plugged it in and it worked fine the bike ran great for about a month then it burned the same one again on the same center prong of the same relay.... Maybe a short somewhere???? Please help!!!! Thank you

 

[midnightrider10]

Sounds like a short to me. I've been dealing with the same kind of issues you've having.

If I was you I'd check all you connections on the front end (Unhook/clean/reconnect), and REALLY check all electrical wires for any chaffing or slightly cut wires. All it takes is a partially cut wire to touch something to cause a fuse to blow.

 

[NashXb12R]

Ok good idea I'll take off the front fairing tommorrow and check the connections!

 

[Rays]

If it was only the centre pin (87) that was melted I would also make sure that the female socket it fits into is clean. A slightly resistive connection will dissipate quite a bit of heat when higher currents are involved.

Pin (30) and pin (87) are connected by the action of the relay so logically if there was high enough current being passed to cause damage it should effect both pins on the relay.

 

[NashXb12R]

Yea so I did what u both said took the faring off cleaned all connections, took the relay box completely apart and cleaned everything in there including wires and put it all back together and it seems fine... We will see if I blow another relay!! Until then I keep 3 extras in my back tool tray incase it goes while I'm riding! Thanks for the Advise!!!

 

[rustyxb12r]

@Rays

You are totally right! At least in my case. I have the same year and make, and had the same issue years ago. You're cure is right on the money!

2 years, no blown relays.