What would cause a starter relay to fail?
I have gone thru 4 relays within 2.5 years.
Fuse does not blow. The relay, when new, starts the quad fine, but after time, it will start clicking fast but still finally make the connection to send power to the starter motor. Eventually, all I would hear is a faint click, but no start. Voltage reads 0v on the starter motor post when trying to start after total failure.
I can jump the relay. connecting battery pos to the starter motor wire and start the quad without any issues. I checked the ground wire from the battery and the wire from the relay to the starter motor, both have no corrosion or are in tact, no cuts/slices/short possiblity.
Can any of the other wires; iginition key, neutral safety switch, Run/Stop wires going to the relay cause it to fail? tia

 

Are you buying aftermarket? Or OEM? and what machine are you working on?
In my experience aftermarket electronics are not up to par.

 

Thanks for the quick reply.

It's a 2004 Yamaha Grizzly 660 with a winch/plow and has grips/thumb heater.
I'm planning on replacing all the wiring and will try with an OEM this time.
I also notice that the Neutral light on the dash doesn't light up as it used to.

 

good luck

 

Yes, ignition switch or the wire to/from it could be the culprit, but my guess would still be bad battery connection or bad earth. Did you remove the frame earth, clean it, and put it back. For some reason Yams are prone to problems with earths, visually they look fine, but don't conduct electricity properly.

 

"Yes, ignition switch or the wire to/from it could be the culprit, but my guess would still be bad battery connection or bad earth. Did you remove the frame earth, clean it, and put it back. For some reason Yams are prone to problems with earths, visually they look fine, but don't conduct electricity properly."

Thank you.
just to confirm, "earth" meaning ground, correct?
Yes, I did unscrew it and check the connections for corrosion, I also checked the resistance on it and although I don't recall what it was, I believe it was what it is supposed to be.
I'm planning on replacing the wires from the battery including the Ground wire.
Would you happen to know the wire gauge I should be using for the wires, the ground seems to be not as thick. I believe the battery wires are 4g. TIA

 

Yes, the terms earth, ground, negative, are interchangeable on quads. There should be no resistance to earth. I use the thickest wire practicable for wires from battery to starter motor and earth. Though the thick wires seldom give trouble, it is almost always a connection or terminal that is faulty.