There is a Facebook group called The Dull Men’s Club and somehow it ended up on my newsfeed. A few of my FB friends are members of the Dull Men’s Club and scrolling through the page it occurs to me that most of the stuff I write about would be perfect for the club. My life has become an endless series of tiny battles to keep motorcycles running. You may think I tinker with the bikes to have something to write about but no, my clunker motorcycles really are a pain to keep running.
The Husqvarna SMR510 in particular requires 5 or 6 hours of fettling for each hour of riding. You may recall the story I wrote about the bike’s kickstand (classic Dull Men’s Club content) and how the bike wouldn’t start. I took the bodywork off and tightened connections, I unplugged and cleaned multi-pin connectors and gave the headlight wiring a re-org to gain a little room behind that crowded area. The bike was starting ok after the work I did.
I took the Husky on a test ride through the mountains stopping frequently and it started fine at least seven times. I figured I had the problem licked and when I got home after a few hundred miles I tried the starter one last time. The Husky wouldn’t start. It wouldn’t start after I let it cool down. It wouldn’t start the next day. Again, I jumped the battery positive directly to the starter terminal and the bike roared into life. I knew the battery was okay so I did what I normally do when I don’t know what the problem is: I bought parts.
The starter relay on the Husky is an odd one to me but apparently the part is used on a lot of ATV’s, small engines and Chinese motorcycles. I looked on a Husqvarna parts site and the relay was $43, plus shipping. On Amazon a duplicate Chinese relay was $7, shipping included. If you’ve followed my moto-journo career at all I imagine there is not a lot of suspense as to which relay I bought.
Even to my naturally cheap psyche the $7 relay seemed too good to be true. So I bought two of them just in case the first one didn’t live up to expectations. Kind of like the old “We’re gonna need a bigger truck” punch line but with relays. The clone relay looked exactly the same as the Husky part except the molded, rubber band mounting bushing was clocked 90 degrees off. I pulled the rubber from the original part and it fit onto the clone perfectly. Things were looking good.
This relay is sort of nifty as it has a main fuse and a spare fuse piggybacked onto the starter relay making for a nice, lightweight, compact…thing. The stock Husky relay had a 20-amp main fuse. The generic unit came with a 30-amp fuse. I pulled on the 30-amp fuse to replace it. And I pulled. I pulled harder. I grabbed the fuse with a pair of Leatherman pliers and gave the fuse a mighty tug.
The relay flew apart; parts went everywhere as the plastic bit holding the main fuse broke away from the body of the relay. The tangs of the 30-amp fuse were still embedded in the fuse holder. I gathered the bits and tried to reassemble the relay but it was too far gone. Good thing I bought a second generic relay.
The fuse in the second relay was as tight as the first one so I decided to use the opportunity to upgrade the Husqvarna’s power supply by 10 amps and left the 30-amp fuse in place. It may never blow without melting the wiring harness. I’ll deal with that situation when it arises.
I took the broken relay apart to see what was in the little black box and it was just like a normal starter relay but in reduced dimensions. I suspect the plunger contact on the OEM relay is not making good contact but there is no easy way to dismantle the relay without destroying the thing.
It’s been five days and I’ve started the Husky each day without a problem. Of course, this proves nothing and I’ll have to bang the bike on some trails to see if the starting issue has really been fixed. One positive outcome from all this jerking around is that I understand the relay wiring now and if it won’t start again I plan to bypass the stock Husky starter circuit and install an entirely new, stand-alone starter circuit/ main fuse with a second push button and relay. It will be a perfect story for The Dull Men’s Club.
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