flasher relay burned out
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  1. #1
    Senior Member technodrive's Avatar
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    i rigged up a new light switch a few days ago. everything worked as it should, but yesterday i killed the bike at a corner smoke wafting from my side panel. old tridon 552 relay was dead and gone, with a good 6 inches of the grey wire burnt up. i got the new "upgrade" 552 (still looks pretty old) and i re-insulated the length of wire.



    now i know that i got it wired 'right' but my question to the wiser is: is there something else i should be looking into (on my wire job or otherwise) or was this just a coincidence? relay was just 13 bucks at autozone but id rather not burn up another out of haste, or worse risk further damage to my machine.



    thanks for input



    -1980 cx500c-
    -1981 gl500i-
    -1978 dt250-
    -1978 xl185s-
    -2000 jackal 1100-

  2. #2
    Senior Member Reg in Bristol's Avatar
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    'Wired right' ?

    It doesnt sound right to me



    The grey wire carries power from the relay to the flasher switch

    if you melted that and toasted the relay then it sounds like a

    dead short situation to me.

    Re-insulating the wire and replacing the relay with out finding/fixing

    the short may be temporary measure until it shorts again

  3. #3
    Senior Member technodrive's Avatar
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    by wired right i mean to say things go where they are supposed to, but i dont mean to suggest that there isnt damage in the harness



    looking at it it may have actually rubbed thru the insulation there at the grey wire behind the side panel. ill look over the whole line again before turning it back on



    Thanks reg



    A bit more tho has anyone experienced a failure in the relay that resulted in this? When it failed that alone may gave caused the short or vice versa. Suppose i should do a full inspection either way
    -1980 cx500c-
    -1981 gl500i-
    -1978 dt250-
    -1978 xl185s-
    -2000 jackal 1100-

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  5. #4
    Senior Member Reg in Bristol's Avatar
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    A failed relay wont burn the grey wire out

    only a dead short will do that.



    lets say for instance you bridged the relay with a wire

    to simulate shorted contacts.

    with the switch in the centre position, nothing happens

    when either side flasher is selected, they come on and stay on until switched off

    No real harm done, just no flashing.

    ( if you wanted to get busy with your thumb, you could do this if the relay failed)



    If, on the other hand, the grey wire instead of going to the switch/flashers

    finds a nice path to ground.

    the high current is limited only by the fuse and if its say a 10A one

    this is more than enough to melt the wire insulation.

  6. #5
    Senior Member technodrive's Avatar
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    Quote Originally Posted by Reg in Bristol View Post
    A failed relay wont burn the grey wire out

    only a dead short will do that.



    lets say for instance you bridged the relay with a wire

    to simulate shorted contacts.

    with the switch in the centre position, nothing happens

    when either side flasher is selected, they come on and stay on until switched off

    No real harm done, just no flashing.

    ( if you wanted to get busy with your thumb, you could do this if the relay failed)



    If, on the other hand, the grey wire instead of going to the switch/flashers

    finds a nice path to ground.

    the high current is limited only by the fuse and if its say a 10A one

    this is more than enough to melt the wire insulation.


    ah i see what youre saying. didnt really think this one thru

    thought to myself, 'oh, the relay is all broken and melted so i may have shorted itself when the leads came out.

    but the relay couldnt very well have melted without shorting first eh? haha



    wait now that makes sense to me again...
    -1980 cx500c-
    -1981 gl500i-
    -1978 dt250-
    -1978 xl185s-
    -2000 jackal 1100-

  7. #6
    Senior Member technodrive's Avatar
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    I believe ive found the root of my issues. There was a second relay wired in behind the headlight bucket. O_o

    Short trip to the gas station suggests all is well. (Knock on wood)
    -1980 cx500c-
    -1981 gl500i-
    -1978 dt250-
    -1978 xl185s-
    -2000 jackal 1100-

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