Stelvio startus interuptus which relay

[Markcarovilli]

Trying to figure where/how the fix is applied.  Is it wiring going to Relay #3 Start-up relay or #4 Start-up Maintenance relay. 

Working on winter maintenance list and this is one that I want to address now rather than later.

Thanks,  Mark

[Zoom Zoom]

I didn't get hung up on any of that myself. Here is what I did.

1. wire
2. eye ends
3. fuse
4. male and female spade ends
5. 40 amp relay from the parts store.  (30 would work but the 40 had a metal mounting tab.)

You unplug the wire from the starter solenoid, and use that as the trigger wire on the relay. )I made an extension so the original connector is still near the starter.)
The other side of the relay needs a ground to complete the circuit. That was back to the battery in my case.
The new hot wire goes to the relay, and the other side of the contact goes to where you removed the original wire off the solenoid. The fuse will go in between the battery and the new relay. I soldered the fuse into the feed wire. Plug all the spade ends into the right places and you're good to go. None of the factory wiring is chopped and could be returned to factory in just a few minutes if you ever wanted/needed to. I located teh relay under a screw in the small triangular cover beneath the seat on the left side. Most time consuming part was making the wires the proper length and soldering the ends on the wires. When finished, everything works as usual for the starter circuit.
 


John Henry

[Kiwi_Roy]

http://www.thisoldtractor.com/guzzi007/schematics/2008_Stelvio.gif
Run a better feed to the common yellow wire to relay 3 & 4 bypassing the ignition switch.

Zoom Zoom's solution will work also, what he is doing is bypassing the ignition switch which is the weak link in the chain.
It's only the initial inrush current that need boosting, the small relays used in the older Guzzis have an inrush current rating of 100 Amps.

As I have explained many times the starter solenoid will draw 50 Amps if it gets a chance, too much resistance and it doesn't have enough current to pull the gear into mesh, just sits there and clicks. Once the starter is engaged (past the dreaded click stage) the solenoid current drops down to ~10Amps.
A typical start circuit wiring will only supply about 35 Amps and barely work, with a direct feed to the start relay it will engage the starter in half the time.
 
Update June 25 2025
                               I just did a drop test on my 2014 V7III Special
It turns out that on this bike the Inrush current to the starter solenoid is just over 47 Amps
So far the bike wiring is handling that but I'm ready for it too fail.
Roy

[Phang]

I have the same setup as Zoom Zoom except that i use a fused Hella relay.

[Zoom Zoom]

Phang, that is pretty cool. I had not seen a relay with a fuse integrated into it. Slick!

Mainly, I did what I did because the relays and most fuses on the '09 Stelvio are up in the front right corner of the body work where they are hard to get to. My solution was easily accessible.

John Henry 

[Phang]

Hi John, it is a neat little relay abiet rather costly.

The pins layout is different from the Bosch automotive relays, if you wired it using a relay socket, a defective Hella fused relay is not interchangeable with the Bosch relay. I think it will pop the solenoid the moment you plug it in if  [85] is grounded. I use labeled loose insulated female connectors so that I can have the option to use a more conventional relay incase the Hella fail.

Hella Fused Relay


Bosch


I connect the hot wire [30] to the starter motor positive post instead of the battery

[ohiorider]

Trying to figure where/how the fix is applied.  Is it wiring going to Relay #3 Start-up relay or #4 Start-up Maintenance relay. 

Working on winter maintenance list and this is one that I want to address now rather than later.

Thanks,  Mark

Check your regular email (not PMs here.)  I sent you the instructions I received from Todd Haven several years ago.  I think (??) you indicated yesterday that you already had a 'startus interruptus' kit from MPH.  I could be wrong.

Bob

[Huzo]

I'm just gunna run a check here. On my Norge, I just ran a good solid wire from the battery, through a 40 Amp fuse, removed the yellow wire complete with its male spade from the plug, sealed it off and whacked the new wire with new male spade connector straight in the plug, replacing the original one. The new wire is about 9" long, (can't remember what I measured it with!). Anyway, is that OK ?