Relay question

[tim0409]

I’m struggling to trace a fault (will crank but not fire) on my BMW Xcountry and I am slowly working my way through the wiring. I would like to replace the plug on this relay (see below) but I’m struggling to find one - any ideas? I don’t think it relates to the issue I’m having but would like to fix it in any case. I could use spade connectors straight on to the pins but would like to keep in standard if I can.
Thanks

[Caddyshack]

I think you might have more success using a pin extractor to remove the pins, fix the wires by soldering on new ones (if you can’t replace the pins) and then use the plastic housing that you have.

[Jazoli]

Caddyshack said:

I think you might have more success using a pin extractor to remove the pins, fix the wires by soldering on new ones (if you can’t replace the pins) and then use the plastic housing that you have.

Agreed I was typing the same, just depin the connector and re solder/crimp the wires.

[tim0409]

Many thanks, that’s a good suggestion. The local BMW specialist can’t look at it for 6 weeks so I’m going to be on a steep learning curve learning bike electrical systems!

[black-k1]

Given the wire colouring in the picture make sure you clearly label each one and where it connects before you disconnect. Ideally you'd do 1 pin at a time but there may be limited space for doing that.

[gareth_r]

I don't know if this will help in your search...

Piaggio (Guzzi, Aprilia) also use the LI L5A relay.

Looks like the Mitsuba rc-2208 is an equivalent that is used by Honda.

[Bodo]

tim0409 said:

Many thanks, that’s a good suggestion. The local BMW specialist can’t look at it for 6 weeks so I’m going to be on a steep learning curve learning bike electrical systems!

This looks like standard 6.3mm spade contacts. Yours might look like this


Note the little metal spring on top: this retains the contact in the plug housing. You may reach and unlock them with a small screwdriver.

The good news is: every auto electrician who does 1990s cars will not only be able to replace the contacts in minutes, but they will also have pliers for F-crimps and a box full of replacement contacts too.

[tim0409]

Thanks Bodo. I’ve just received the wiring diagram from an owner on another forum, and the relay basically turns the headlight off when you are starting the bike. It’s just a standard relay so presumably I could buy another relay with harness and connect that instead of depinning this one?

ETA I’ve just ordered a crimp tool and connectors so will reuse the existing connector and relay. Thanks again for all the helpful posts.

Edited by tim0409 on Friday 22 March 20:39

[tivver500]

Have a look at this page which could well give you what you need.....

https://www.vehiclewiringproducts.co.uk/c-219-rela...

[Biker 1]

tivver500 said:

Have a look at this page which could well give you what you need.....

https://www.vehiclewiringproducts.co.uk/c-219-rela...

I've ordered stuff from these guys - very good service would definitely recommend....

[tim0409]

I managed to repin the existing relay. I spent quite a few more hours tracing the non starting fault, and it was a faulty starter relay that was hanging down behind the engine, having had the wiring badly repaired before. I replaced the relay with a spare and it immediately fired into life, which is a result as my bike has been off the road for a few weeks. Took it for a test run and it’s perfect.

Rewired headlight relay -



Back on the road….

[Bodo]

Nice work, thanks for the follow up!

[HairyMaclary]

Congratulations and well done. I had an issue with starting and charing on a Piaggio mp3 400 which was down to a fried starter relay wiring. The whole thing caught fire!

Cool looking BMW. I had no idea these existed!