Customer Accessory Circuit completely DEAD! Any thoughts?

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03-25-2023, 12:20 PM
hypurone

Customer Accessory Circuit completely DEAD! Any thoughts?

Got a weird one here. I have had this bike since new and have the Signature Light installed via the front accessory circuit under the frunk tub. Has worked fine for 7yrs. Found it not working the other day and in testing, there is NO voltage in this circuit. Not just on the downstream side of the fuse but completely dead. No power at either side of the fuse.

My heated grips have also stopped working. ALL FUSES are good! I cannot find any material that is clear and concise on the relay(s) situation. Including the load shedding relay... I am going to see if there are any identical relays I can swap around for testing next but thought I would drop a line here for additional info....

Thoughts?
03-25-2023, 12:28 PM
Knizar

Did you check for power with key on and RUNNING, some power sources need ENGINE RUNNING to initiate power. Just a thought from previous encounters.
03-25-2023, 01:07 PM
hypurone

Quote:

Originally Posted by Knizar

Did you check for power with key on and RUNNING, some power sources need ENGINE RUNNING to initiate power. Just a thought from previous encounters.

Oh yeah... I worked as a paid automotive tech for 22yrs before hanging it up... I have rewired the Sig Light on the GPS circuit te get it working but need to understand how the circuit went completely dead! I have yet to dive into the heated grips as I need a better understanding of what relays control what including the "shedding" relay....
03-25-2023, 02:54 PM
hypurone

OK, the weird just got weirder! I switched the relays around with other identical ones and VOILA! The circuit is live again AND the circuit that I took the relay FROM is still working with the relay from the accessories circuit!! WTF!?
03-25-2023, 03:07 PM
BLUEKNIGHT911

Quote:

Originally Posted by hypurone

OK, the weird just got weirder! I switched the relays around with other identical ones and VOILA! The circuit is live again AND the circuit that I took the relay FROM is still working with the relay from the accessories circuit!! WTF!?

" WTF "....exactly ..... Mike:thumbup:
03-25-2023, 03:19 PM
Gwolf

Quote:

Originally Posted by hypurone

OK, the weird just got weirder! I switched the relays around with other identical ones and VOILA! The circuit is live again AND the circuit that I took the relay FROM is still working with the relay from the accessories circuit!! WTF!?

The relay was stuck. Moving it around and the off/on a few times broke it loose, and it started working right again. Relay plunger might have some corrosion or dust.
03-26-2023, 10:44 AM
Navydad

Quote:

Originally Posted by Gwolf

The relay was stuck. Moving it around and the off/on a few times broke it loose, and it started working right again. Relay plunger might have some corrosion or dust.

:agree: Seen it many times.
03-26-2023, 11:27 AM
hypurone

Quote:

Originally Posted by Gwolf

The relay was stuck. Moving it around and the off/on a few times broke it loose, and it started working right again. Relay plunger might have some corrosion or dust.

Quote:

Originally Posted by Navydad

:agree: Seen it many times.

Normally I would agree, but these things are smaller than the average relay and very stout in nature. There is NO flex in these things at all... Yes I have seen it before in all my years but that was on the larger less compact automotive units... OH well, it is what it is I guess. :banghead: I have some new ones coming for spares... ON WITH THE RYDING! :doorag:
03-26-2023, 11:41 AM
Gwolf

Quote:

Originally Posted by hypurone

Normally I would agree, but these things are smaller than the average relay and very stout in nature. There is NO flex in these things at all... Yes I have seen it before in all my years but that was on the larger less compact automotive units... OH well, it is what it is I guess. :banghead: I have some new ones coming for spares... ON WITH THE RYDING! :doorag:

Doesn't really have to be on a plunger shaft. The older ones might have pitted contact surfaces. Possible something got between the contact points and held them off enough to prevent power from passing through them. Even the sub-compact solenoids have contacts.

Ants love electricity. Not sure why, because it fries them between the contacts. Lost count of how many times I have had to clean the ants out of pump pressure switch contacts.

Could have been just some pitting on the contacts. No way to know for sure (unless maybe you take the relay apart when you replace it).

Old points and condenser ignition it would almost certainly be pitting......... Spyder ignition, not so much, but still a possibility.