Alton starter, Norton switchgear issue. (2020)

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Hi Derek, not yet. I have a 12 volt relay arriving tomorrow. Ia am going to wire the switch through that as advised and see if it fixes it.
 
Ok, as per Fullautos suggestion, I fitted. A relay yesterday. Switch seems to work perfectly. Will ride it in the next few days to test properly.hopefully that the solution!
 
It would still bug me. We don't really know the root cause of the problem. It worked before without the relay then died from something - a corroded contact maybe? So that may be still lurking around.
 
I would still suspect the Alton relay, the low current side looks to need to much current to work, this current is now being provided by a 2nd relay. If the Alton relay low current contacts are corroding then eventually even the new relay will not provide enough current. Other suspect is the wiring to and from the button and the button contacts but it is providing enough current to close the low current side on the new relay.
 
"I would still suspect the Alton relay, the low current side looks to need to much current to work,"

My original Alton relay/Norton OEM 'extra' switch have been working perfectly since I installed the Alton in '12. So clearly it and the OEM Norton switch are perfectly capable of doing the job. I agree with Batrider - the added relay is not necessary, it just masked whatever is causing the problem - bad connections, dirty contacts, etc.
 
All connections have been checked the loom is relatively new. Anyway it will be more thoroughly checked over winter.
 
The Lucas switches have a tiny contact area that can become corroded after 50 years. You need to take a points file and clean the contacts properly.
 
What brand and model of relay does the Alton kit use?

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cliffa said:
I'm not sure jimbo. Alton should be able to help you, but any 12v solenoid should work. No chance to clean up or replicate/ the contacts?
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Alton does not answer any of my emails.The coil wires are tiny and would be a real hassle to try to reconnect/ solder . The contacts are copper, I could probably make something up, but I just as soon have a new one. I bought this kit used and I really got screwed( story to come), lesson learned do not buy used electronics and electrical components . I would like to find the same relay , as I found a perfect place to mount it and others probably wont fit as well. I tested the relay before I started the install it clicked nicely, but did not load test the contacts.As I get older it seems I am making more and more mistakes.:confused:
 
jimbo said:
Alton does not answer any of my emails.The coil wires are tiny and would be a real hassle to try to reconnect/ solder . The contacts are copper, I could probably make something up, but I just as soon have a new one. I bought this kit used and I really got screwed( story to come), lesson learned do not buy used electronics and electrical components . I would like to find the same relay , as I found a perfect place to mount it and others probably wont fit as well. I tested the relay before I started the install it clicked nicely, but did not load test the contacts.As I get older it seems I am making more and more mistakes.:confused:
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That's unusual, they have always been very responsive to me. Try paul@alton-france.com
 
From the burn marks you need a solenoid that takes a higher amperage, a replacement Alton relay is likely to fail the same way. Aprilia's have the same problem and the recommended replacement is a Yamaha solenoid but avoid the Chinese copies or you end up back at the start.

Yamaha 4KB-81940-01
 
Two things that I can think of to reduce the current going through the starter switch would be:
1) Use a relay to control the starter solenoid, I'm pretty sure this was standard on older Harleys
2) Install a snubber diode across the solenoid control wires. This helps to limit back current when the switch is released. It's less effective on (+) earth systems but will help.

As a side note: If I was running electronic gauges this is something I would really consider.
 
Just noticed some recent comments on this thread.
I fitted a relay to reduce the current through the switchgear and had no further issues.
I then fitted a NOS switch.
All I can say to people having issues with Alton is that I have contacted them many times, the only time it took a while for them to get back to me was a French holiday.
Paul speaks English and will answer the phone.
I don’t speak French, never been an issue.
Good luck to all.
 
Any new cheap solenoid will work . Yes the main contacts burn over a while but think of the amperage between the main contact points to turn over an engine. Likely the biggest draw on the whole machine. Don't keep on it if the bike won't start immediately. The contacts will burn.
 
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