620 - engine shuts off 1 block from house

[Speeddog]

those are the little square/cube things near the 40A fuse right?  just want to ensure I'm replacing the right thing.


Do you think they'd have them at the local auto parts or electronic supply house? or only at the dealer?

Yep, them's the ones.

Tyco V23073
NAPA AR634
Bosch 0 322 207 307
CarQuest RY620
BorgWarner R3223
MOPAR 56006846

There's probably more.

I was going to say to give a call to Ford Electronics in Buena Park, but seems they're gone.  
That place was epic.

[Privateer]

awesome, thank you.  I'll get to autozone tomorrow maybe thursday, weekend for sure and report back.

[Privateer]

well, interestingly enough. autozone had a match for one of the part numbers, the NAPA one I think.

however, the new relay has 5.. posts? blades? on it, and the ones in the bike have 4.  there's a row of 3 on the bottom, the one in the bike looks like that post is snapped off.

they only had 1 and ordered me another to pick up (or not) tomorrow.

the new one I did get did plug in, and the socket it plugs into has 5 slots.

any foreseeable problem with the NAPA relay with 5 posts?

[Speeddog]

~~~SNIP~~~

any foreseeable problem with the NAPA relay with 5 posts?

Nope, no problem.

[Privateer]

thank you.
replaced both, started up and idled fine.
took a ride down to the gas station and it did not die (about 3x as far as it went before without dying).

took a spin around town and seemed to be OK.

looks like I'm in the clear for now.  Thanks everyone, but especially thanks to Nick and Howie.  You easily saved me a couple hundred dollars of shop diagnostic time.

[Howie]

Glad your problem is resolved.

[Privateer]

and maybe it's my imagination, or after having to commute by car for a week, but man my bike seemed to run much better yesterday.

[Privateer]

in case you're wondering what's inside

[Nekkid Tim]

Great thread, great result!!!   

[Privateer]

well...

it happened again today.
same symptom.  shut off at 40mph at 4,000 rpm, while lane sharing.  pretty exciting.

pulled over, key off/on.  no gauge sweep, but started up.  got me the rest of the way home 15 miles, with a gas stop along the way, and seemed to be OK.  Headlight bulb is out again.

I had it idling in the driveway when I got home and noticed there was 'smoke' coming out of the exhaust.  not smoke really, but visible vapors, which I can't say I've ever noticed before.

[DarkMonster620]

I'll upload a link of the repair manual . .  for some reason I think this is happening because of a "faulty-loose connection"

edit:

user's manual with electrical at end
file:///C:/Users/Carlos%20Brewer/Downloads/M620_800_1000_2004_it_en_fr_de.pdf

[koko64]

Has the rubbing loom near head stem been covered?
Or loose connection as you say.

[DarkMonster620]

Has the rubbing loom near head stem been covered?

NOPE

Or loose connection as you say.

Electrical gremlin . . . need to get home to upload link for m620 manual in English . . .

[ducpainter]

Koko makes a valid point. I believe the kill switch wiring is still in the same spot in the harness near the steering head tube.

A frayed wire in there could cause intermittent shutdowns.

[Howie]

Try moving the handlebars from lock to lock while idling.