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Starter motor relay/solenoid issues
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Hi All,

My 2015 MT-01 has an electrical issue that I have not been able to fix. The starter solenoid keep burning out, some times it keeps turning the starter motor (battery has to be disconnected to stop this) or the bike just stops (loss of power) and the solenoid is not useable/burnt out. So far I’m on solenoid #4.

Has anyone had this problem and how was it rectified.

Surly my bike is not the only bike to ever have this problem.

Thanks in advance for any help.
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Re: Starter motor relay/solenoid issues
« Reply #1 on: »
Hi mate, yeah I had this problem a few years back. Solenoid kept sticking open on start and the only way to stop it was disconnect the battery. Emergency stop did nothing ... it just kept turning over until the battery was disconnected. My bike was still under warranty but every time I took it in the problem would go away. Happened twice. They did replace a relay under the seat which they seem to suspect could cause the issue. It was not the starter relay. Not sure which one though.
I do recall an issue with starter relay selection. The first relay the shop supplied me was not rated for start current these starters use so I did upgrade the relay to a higher current. Maybe check the current rating on starter relay first. Haven't had the problem since. Cheers Steve
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Re: Starter motor relay/solenoid issues
« Reply #2 on: »
Thanks Jota,

The last relay was original Yamaha part, and still burnt out.  At this stage I’m thinking it may be the starter motor getting old and drawing too much power causing the relay to over heat and fuse it closed.

This results in burning out the relay.

I will pull out the starter motor and check it. Has anyone done this if so is there an easier way to get the oil tank off.

Thanks again
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Re: Starter motor relay/solenoid issues
« Reply #3 on: »
Update,
The starter motor has burned out and will be replaced. Hopefully I can get one from a motorbike wreckers. If not it’s $1200AU for a new one.  The issue is what caused the problem.  F&#k it.
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Re: Starter motor relay/solenoid issues
« Reply #4 on: »
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Re: Starter motor relay/solenoid issues
« Reply #5 on: »
Robbed from another post

ref YS-31N Starter/Yamaha/Motorcycle
Yamaha 4WM-81890-00-00 4WM-81890-01-00
Description: Starter
Supplier: EMS
OEM(s): Mitsuba
Starter Family: Mitsuba SM13
Voltage: 12 Volts
Rotation: CW
Teeth/Splines: 22 Teeth/Splines
Approximate Weight: 3.6 lbs / 1.6 kg

$141.95
YAMAHA Powersport MOTORCYCLE XV1600A Road Star 1602cc 1999-2003
MOTORCYCLE XV1600AS Road Star MM Ltd 1602cc 2000
MOTORCYCLE XVZ1600AT Road Star Silverado 1602cc 1999-2003

Try this one, a lot cheaper.
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Re: Starter motor relay/solenoid issues
« Reply #6 on: »
Thanks Rocker, I’ll look into it.
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Re: Starter motor relay/solenoid issues
« Reply #7 on: »
With this problem generally, has anyone checked the actual starter button? Is it stuck "on" so keeping the starter turning?
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Re: Starter motor relay/solenoid issues
« Reply #8 on: »
Yep checked and cleaned the starter button, it’s working fine. Doesn’t appear to be the problem.
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Re: Starter motor relay/solenoid issues
« Reply #9 on: »
Hey Mastiff, just a thought but I wonder if the burnt out starter motor is the cause or the consequence. When this happened to me twice the bike started OK but I noticed a funny noise so turned the engine off and bloody hell the bike was still turning over on the starter motor. Hit the emergency stop and still its turning on the starter motor. Ended up having to disconnect the battery to stop the starter. So my concern was what would happen to the starter if it kept engaged for a long period. Would be interested to know how you get on. Cheers mate ... Steve
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Re: Starter motor relay/solenoid issues
« Reply #10 on: »
This is what happened to mine, the reason is yet to be determined.
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  3. Starter motor relay/solenoid issues