Check Start Auxiliary Relay; Checking The Auxiliary Starting Relay For Faultless Operation; Checking The Diode - KTM 400-660 LC4 1998-2005 Repair Manual

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A
B
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Check start auxiliary relay

– Remove headlight mask and remove the start auxiliary relay.
– Connect the start auxiliary relay to a 12 V battery as shown in the
illustration.
– Use an ohmmeter to measure the continuity between the terminals
A B
and .
Reading 0 Ω relay intact
Reading ∞ Ω relay defect

Checking the auxiliary starting relay for faultless operation

Preparation:
– Pull the auxiliary starter relay out of its holder.
– Connect an ohmmeter or a continuity tester to the cables of the
auxiliary starting relay (colors: red and red/white).
– Perform the tests in the order indicated below. The auxiliary starting
relay must respond in either of the following two cases:
● Put in a gear and slowly pull the clutch lever. The auxiliary starting
relay should respond when the lever is pulled approximately half of
the overall distance. If this is not the case, please check the clutch
switch. Keep an eye on the neutral control lamp while performing
this test. The neutral control lamp should not light up. If it lights up,
check the diode.
● Switch the transmission to neutral without previously pulling the
clutch. The auxiliary starting relay should now connect and be
tripped as soon as a gear is put in. If this is not the case, please
check the diode and the neutral switch.
NOTE: Connecting of the auxiliary starting relay is always accompanied
by a faint clicking sound. The ohmmeter or continuity tester indicates
continuity while the auxiliary starting relay is on.

Checking the diode

NOTE: Diodes conduct current only in the direction indicated by the
arrow, preventing the conduction of current in the opposite direction.
Two different kinds of diode defects can be distinguished:
– The diode conducts no current at all.
– The diode conducts current in both directions.
Diode defects can lead to different kinds of trouble, depending on the
type of defect.
NOTE: The diode is located in a 2-pole connector.
Checking for faultless operation:
– Remove the headlight mask.
2
– Pull the diode out of the connector.
– Connect an appropriate ohmmeter to the diode and check for
continuity.
– Connect the ohmmeter in the opposite direction and check if the
diode prevents current conduction in the opposite direction.
7-12E