I also had the same engine cuts out on my Interceptor (Euro 4). I cleaned all the connectors, changed the relays to Bosch like you but the engine cuts persisted. The Royal Enfield dealer changed the side stand switch, the drop switch, the general key switch and I still had occasional engine cuts. This went on for 6 months before he found the faulty part which was the crankshaft sensor (DTC code P0335). No more cuts out since this part was changed (under warranty). I hope this helps. Regards from France.
Interesting, i had the same trouble, replaced relays which fixed it for around 4.5k miles... its now back again now and replacing relays for hitchcock ones hasn't made any difference. i have 2 fault codes in the ECU memory P0651 and P0641. Interestingly flicking the kill switch on and off resets the fault for a bit and you can continue riding
@@ohwell2790 it's done 37k miles... Hardly new. But agreed it's starting to piss me off. Shame, as the engine and frame is class. Guess that's what you get when you buy a budget bike.
I had the exact same issue on the GT650 Continental. Would cut out randomly, especially at slow speeds. I saw this as a fix on an Indian based Enfield chat room, and so cleaned out as much of the white grease as possible. The bike would cut out 2 or 3 times on a 30km ride. Since cleaning the relays, I've not had a single cut out in almost 3000km, so I'd be confident that you have sorted it!
Other blogs recommend degunking the relays on the Interceptor / GT as a precautionary measure. I know two other guys who have had breakdowns on theirs, which seem to have cleared after a good degunk. I did mine when it was new, loads of this white, insulating goo came out!! Hope this fixes the problem for you too, and love your description of good old fashioned electrical engineering..!
A blast with compressed air (if you have a compressor available) would blow most of the grease out of the connectors (cover with a cloth or you might cop a face full or spray it all over the bike), then a clean up with the correct spray would make the job faster and easier... Excellent video, you explained the operation of the relays and testing them very well!
I was having a similar issue ...it was the fuel pump failure..so bike stops completely. but what you explained is really useful in regards to the relays..thank you
After watching this as a precautionary measure i also cleaned out and replaced the relays with only the battery cut off switch needing attention also. Thanks for the info 👍😎
Well done video. I too heard of the grease and rely issues on these bikes. So, I purchased full replacement set of relays from Hitchcock's for my Interceptor and new Classic 350. The plan is to clean out the grease and replace them on both bikes during winter months.
The ground and hot harness plugs has this same problem, pull those apart and clean as well. I have a brand new US model 650, and everything was packed just like yours. My new Himalayan the same way. I also replaced all the relays on both bikes. Cheers Dale
The grease they use on connections is a silicon cheap grease often used here to pull cables inside sleeves. Despite its aspect, it is quite effective at preventing water ingress. This system is very common in India where automotive connectors would cost 1/10 of to total bike price. Remember, a new Bullet 350 in India (witch is already a luxury bike in a 110cc country) cost just 1700$ with 1 year insurance. I recommand to stil put A LOT of dielectric grease in you connectors, beacause they are not insulated.
I went through the same fixes as most commenters, replacing relays and cleaning connections. It was a great improvement, but I still had occasional cut-outs. The problem was finally resolved when I replaced the tip over sensor
From other RU-vid postings, your experience with the bike's relays is CLASSIC! Your video on the problem, though, is outstanding, and your methodical diagnosis is excellent. I had the same problem with my Italian car, and that was solved with a solid-state relay (immune to vibration), but... the downside of solid-state relays is that their failure mode is Contacts Closed, perhaps leading to a small fire.
Hi Dave. Thanks for the feedback on the video. I do wonder why mechanical relays are used on bikes in a world of solid state. But maybe safety and cost plays a part.
Had a similar issue with the fuelling relay on my interceptor. Cleaned all that white grease away with WD 40 and to be on the safe side I changed the relay. Happy to say been fine since 😊
Dielectric grease is an insulator and is mainly used for preventing corrosion. The tiniest smear is all you need, plaster it on and you'll be back where you were
Brilliant diagnostic work! The grease packing by Royal Enfield is a known issue and no one seems to know what they are trying to achieve in doing this. It's overkill for simple corrosion prevention.
Yep snap with yours and others problems. Mine cut out whilst overtaking on a busy dual carriageway....not good. Had it recovered via Enfield recovery service back to the dealer who put in new relays and gave it a clean as on your video and it's been faultless since:)
A very informative, intelligent video. I have heard of problems originating from this set of four relays, I have not had any trouble but the information about the Bosch replacement relays is very useful. Well done from an Interceptor owner and electrician.
I have the same yaar and model..... only about 5200 miles ..... as to date no issues.. but I did purchase spare relays, a relay tester,, and a OBD unit to pull any codes. I'm very pleased with the machine .. recently completed a 2000-mile solo adventure. :)
My experience is almost identical to yours. I replaced mine with the Hitchcocks upgraded relays and not a single hint of a problem since. Great video mate 👍
I've got 600 miles on my '22 Interceptor and will be investigating the relays for this goop immediately. I spotted it on the horn contacts and thought it peculiar for electrical connectors..... I also found a loose pin in the taillight harness plug when I lost a rear indicator.. Thank you for yet another great and helpful video and cheers from New York!
First thing I did on my euro v, exactly the same, literally smothered in grease. Just done 1500 miles and no problems yet 🤞 Lovin the videos bud, lovin the bike too 👍
I changed out the relays on my Euro 5 Interceptor, not long after I bought it, after hearing so many owners were having problems. I purchased the replacement relays from Hitchcocks. Cleaning off the OEM grease was an absolute ball ache, although it was worth it. Thanks for the info regarding the alternate Bosch relays. The visuals and your relay test explaination were excellent. Thanks for that. I'll definately save your video for future reference. Top Job and video as per normal. Many thanks and here's wishing you many more trouble free miles.....👌
For me it was my starter. I cross referenced the relays and ordered the Bosch ones from Amazon. I didn’t know which was which so they all got replaced.
Great video!! I haven’t had this issue, but now that I’ve watched the video I bet it will come around soon 😅 I’ll know where to look and how to fix it! Very informative!
Great video , mine lasted 10 month before I realised the white grease issue, cleaned with Wurth industry cleaner as nothing would clean it 100% worked fine for a while then started with bad tickover and. It out so replaced with expensive Hitchcock motorcycles £40 for 5 , but forgot to do a cold start reset and it cut out within 100 yards , redid the cold start and it’s much improved , however I still have it in the back of my mind what if it happens when overtaking? Bike I’d two years old now and has been great other than this issue Would recommend cold start to hot engine Without any throttle movement takes about 15 to 30 mins. Yea so for your video Seen another video re the carbon dump valve and to remove it but not going to do that just yet
G'day mate from Australia, had the very same problem on my 2021 Interceptor and after cleaning I applied a small amount of dielectric grease, this grease has a good conductivity and since doing that, absolutely no more problems, also checked any connection's l could find on the bike, cheers, Neil 🤠.
Hi, Just thought i would pass my experience on to you and your subscribers. i was captivated by the reviews and simplicity of the RE Himalayan had a test ride on one last June and was really surprised. You can easily flat foot it and its road presence is larger than you think, it is under powered but we have a lot of country winding roads and a lot of easy green lanes near us. Its no Honda but gives you more confidence on gravel roads because if you drop it you won’t damage anything its built like a tractor. I swapped the CB500X for a 2022 second hand Himmy with all the bells and whistles metal panniers, engine Guards,.spot lights with only 147 miles on the clock. At 300 miles i decided to change the oil and filter as suggested in the service schedule made sure i took it easy for the first thousand miles. I went to north Wales with my two sons for a three day tour every time we stopped for a break or get petrol the bike would not start first or second time but would start eventually. After some research on you tube it was a faulty relay switch so i replaced them all and the problem was fixed. The first week in January on the first dry day i went for a spin, about three miles from home i was going uphill at 50mph and the engine just died it would turn over but not start so i let it cool down turn round and head down the hill to bump start it, It did go and got me home but was making a horrible rattling noise. I got in touch with royal enfield they picked it up and took it to the nearest dealer to me. They got in touch on Monday its got to have a top engine rebuild camshaft new barrell and piston total cost £895.00, so for a bike that is only 9 months old and covered 2000 miles is a lot of money. Royal enfield won’t cover the cost because i did the first oil and filter change thereby invalidating the two year warranty. Foot note ... I passed my bike test in 1972 on a Honda S90 Sport and since then have had many bikes, i am no mechanic but have always changed the oil and filter on my bikes at three or four thousand miles weather it needed it or not, in my mind i thought it would prolong the life of the bike. So to sum up if anybody is interested in a second hand R E Himmy make sure it has got RE approved service history. All the best Bob, Show less
Yes and this answers the question about mods and servicing your own bike. It will invalidate your warranty as us poor bikers are not covered by the same exemption covering cars. Sorry to hear about your story.
@@WildlifeMoto Yes all good, final ride of the season tomorrow. Thankfully I've not had the relay issue yet but I think your method is a good one - swapping out for Bosch.
Happened to me on several occasions on my new Interceptor - except that it re-started straight away. Anyway I cleaned off all the excess grease AND replaced my relays with Hitchcock ones. Been ok ever since. As ever many thanks for your superb videos. Cheers!
Nice, informative video! Keeping fingers crossed that was it. Intermittent problems are the worst! I actually prefer things to poop out completely, thus making the cause of failure obvious :) Btw i swapped the Tuono for a 2022 MT-10, this far i am happy with it! Cheers!
I lost you Guru at electo magnetic something or other but trust every word you said. For anyone else in the same boat, change the relays like the man said 🙂👍
Bought a 2019 Interceptor about 4 months ago, did a 9hr ride a couple of days ago, no problems, next day after about 60 - 70 km it just died, just like hitting the kill switch, did it again heading back to motel, cleaned out the grease, still happened, am in process of finding issue. (Update), Replaced all 4 relays, still dies, I spoke to an RE tech, he says only real problem was fuel pump relay, or connections in fuse box for EFI, I tightened up the female spade terminals for the relay with a very thin screwdriver and tightened the terminals for the EFI in the fuse box (added more tension to female terminals) put 4 hrs on the bike this morning and not an issue. Fingers crossed.
I had this cutting out issue too, the engine would totally cut out but electrics would stay on, very odd. Also happened to me at 50mph. The issue stopped for me after removing the booster plug and putting in a new regulator rectifier. I tried many things before the fault went away, I change relays to the hitchocks ones and also had throttle body adjusted and valve clearence done. Glad you seem to have sorted your bike but if it does come back, check your regulator rectifier isnt pushing out really high voltage like mine was, 19v at idle. Ride safe, Cheers
Did this as a preventative measure before the gremlins started stirring. Watching your video, I'm glad that I did. The only issue I've had with the bike is a small oil leak from the banjo joint leading to the oil cooler. Have any other viewers experienced this? My dealer replaced the parts under warranty this week. It was a bit of a mission getting Royal Enfield to play ball initially but they eventually came to the table.
Same thing for my int650, after 18months of ownership (although I was doing 75mhp on the M25!). There are many RU-vid videos showing this problem with the relays, so I just changed them straight away. Touch wood, the problem has not repeated.
The same thing happened to me in May 2022 when I bought a Euro 4 2019 interceptor.I lost total power at 65 mph and revs dropped , no response to revs when throttle opened in neutral.Engine stopped when pulled over.Restarted the bike & went back to normal.I sent bike back to garage , on return i pulled all 4 relays & cleaned up grease on pins & checked relays with multi meter...but I found a reported problem with the tilt sensor fitted behind RHS panel, with reports of cutting fuel off to the engine when bike hasn't tilted say like laying on its side! it was inexpensive to order a replacement tilt sensor and easy to replace 🫰fault has not reappeared in the 600 miles I have rides since.Bought tilt sensor for under £20 just plug bew sensor onto plug that goes to ECU simple job.
I thought that I had escaped this problem on my euro 4 model with just 1200 miles on the clock, but No! The same thing happened to me a few days ago☹️. Surly Royal Enfield should be putting out a recall on this and other effected models too. I still love the bike though!😀
I had total failure which was traced to the positive cable from starter solenoid to fuse box, the single push in connection had arced and melted. Likely water dirt ingress, its under the battery on top of the swinging arm.22.01.24
Different but similar relay issue on mine. Intermittently it wouldn't start, just click. RE dealer first swapped switchgear, then tinkered with the wiring. Same problem. On the third go the mechanic took the relays out one by one and shook them. One rattled so they replaced the lot. Problem solved! 😁
Hi . Tip for removing all that grease is an air line if you have access to one . My husband has a interceptor with watsonian sidecar and was experiencing some stalling issues. If it persists now I’ve cleaned them up I’ll try the bosch relays. Where did you source them please?
Hi Lovely Vídeo. I hope you are right. I have a serious problem with my 2019 RE Cont 650 and it is that the engine cuts off once the Abs comes on and then the engine failure warning light comes on. I manage to start but after a few kilometers it stops again. One of the times I almost fell. I no longer have confidence in the bike. I hope that cleaning and replacing the relays will solve Thanks!
I too had this issue but the 2nd time it happened I flicked the kill switch off and on again and the bike picked up and drove home OK. After thinking about it I suspected the fuel pump relay and did change it for a slightly uprated one and the problem disappeared. Curiosity made me open the relay where I found a crust of black carbon on one of the contacts which actually just flicked off leaving the contact clean again. I have now changed all the relays and have fastened a spare close by (just in case!).
Wow 😲 look at that grease😁😆😂🤣.Just replace them with Hitchcocks Relays twice the amps & bike idles slightly higher & started stronger.I actually had a faulty relay on fuel pump & bike would loose power on deacelleration so cleaned all the grease off & still did it so got new one's from Hitchcocks & fixed the problem & improved idling & starting.
My bike has a wierd issue. Once it heats up the voltage meter I've installed shows the volts beginning to drop. To the point the low battery indicator turns on when I'm riding. Once i park the bike , and let it cool. The volts spring back up to 14.2-5 levels like from day one.
Anyone know how to clear the little error light off the tacho? Had this problem about 500km ago but still have the little light on the tacho showing constantly.
I hv had this same issue, apparently the ignition switch is loose n needs to be tightened. This needs to be done@ the RE service center. Issue was resolved after the switch was tightened
Same happened with me. It happens when spark plugs gets overheat, check first. Second might be relays, white grease should be replaced or in some cases all the relays, please do share if there is any other issue that occurred this problem for my learning
In my RE GT I also cleaned everything and replaced the relays with the national brand DNI, highly regarded around here and used by major vehicle brands. I didn't have any more problems.
A minha está apagando tudo: motor, painel.... Acontece quando paro ela e vou tentar ligar de novo. Depois giro a chave novamente e ela liga. Isso somente quando está aquecida. Agora ela começou a dar estes apagões andando. Levei na ccs e eles não acharam nada. Comprei estes relés DNI e vou substituir os originais
Hi, nice video, I replaced the stock relays with Panasonic. One question could you tell the brand and model of the left and right handlebar switches? Thanks
My 2019 Interceptor 650 had this after more than 2 years of trouble free riding - engine stall at high speed (50-60 mph!). The bike was already booked in to the dealer for the brake recall so I asked them to investigate and cure. Dealer took one look at the after-market cans, DNA filter and booster plug and sent me home without any care for my safety/their reputation despite me telling them of the RU-vid videos on relay gunk, roll over switch etc! My fix (🤞) was clean the gunk and, as a precaution, replace the roll over switch. No recurrence so far.
I had the same problem and I dropped the bike in a slow u turn as it cut out. Yes brand new Euro 5. I changed the relays and it improved but not fixed. Sent it back and it required an ECU remap! All good now but pretty disappointing for a new machine....
Speaking from several past experiences I've had, sometimes with relays like those, just taking them out and putting them right back in will cure the issue for good.
I have a 2022 Royal Enfield 650 Interceptor with 500miles, or 804 kilometers, When I first start the bike when cold it starts but immediately dies, i have to immediately rotate the throttle to get it up in rpm's to keep it running at higher rpm for a few seconds then it will idle ok. It does this every cold start attempt. I cleaned and replaced the four relays but it didn't help. Did you also have this happen with your RE?
That's not normal. What is the engine speed like once warmed up? Check all the obvious stuff like throttle cable, butterfly, Injector connectors, spark plugs. Then take it to a dealer to check the ECU.
After it warms up the idle speed is normal. I think it is a tight engine and hopefully it will improve with time. I think i will upgrade the spark plugs to Iridium type, maybe that will help
Hi. Does Changing to BOSCH or Denso relays void the warranty? I'm also facing a minor fuel pump issue, but this Relay seems to be one constant issue...
Surly you don’t want to use anything that increases conductivity across a multi-wire plug? Dialectic grease is chosen because it’s insulating but will not reduce the individual conductivity of a spade terminal. The pressure of the connection easily overcomes insulating properties of the grease.
I had the same issue on my interceptor, and seeing most online forums I too changed and cleaned my relays, but the problem still persisted. So I got the fuel pump changed and so far no more cut outs. Anyone had to change their fuel pump also?
I vinyl wrap my continental&anazingly..i saw the same gunk as your video in the rear light connectors🧐 i was stunned,why put it in there haha,but true as its in there
Great, video, I have to say RE owners seem to be generally very forgiving over this issue. First it has been going on for years and seemingly ignored by the company, and second it is potentially VERY dangerous. It's enough for me to discount ever buying the Inteceptor.
I have the same problem twice, firs it was under warranty and they said that the problem was the drop sensor connector, after another year outside the warranty the problem started again, I made a current divider to replace the drop sensor because the ECU needs a current feedback from the sensor……no more issues with that. See my video
The grease in the relay plugs has been highlighted by other RU-vidrs. The little relays you are holding are not man enough to crank the bike. There should be a larger solenoid (usually looks like a small round can). Hope you get bike sorted.
I'd rather have it blow up than have an intermittent fault. Had such on a Ford Fiesta. The main dealer just about called me mad. A back street garage found the fault - a hole in the carb diaphragm.
Testing relays that are intermittently malfunctioning is rather useless. The relays RE uses are five pin units with an unused normally on set of contacts. To make the RE bikes reliable it is not enough to clean off the white grease, the relays should be replaced with four pin Bosh relays (Bosch 033201107). The four pin relays feature a simpler and more reliable SPST construction. I earlier cleaned my relay pins and sockets and that helped a lot, but I was still having these rare failures, so I replaced the relays. At about $6 per relay from Amazon, they are cheap insurance and I haven't had a hitch since and I have so much more confidence in the bike. By the way, a brand new (2022) INT650 came into my shop for 500 mile service and it featured four pin relays, but there was still gobs of white grease (which I cleaned and replaced with silicone electrical grease). The customer reported no problems and I assume it was because RE switched to a more reliable (four pin) relay.
Yes I’ve heard that some of the newer bikes ship with 4 pin relays. I’m not worried about the reliability of the 5 pin Bosch unit + it had an extra pin to secure it to the plug.
I haven't had that problem with my four-year-old Interceptor, but while it's resting over the winter months, I will examine the relay terminals. I would have been inclined to use copper grease - is this wrong?
Great vid. Just one point... is dielectric grease insulating? I.e if it comes between electrical contacts it can stop connection. I.e you want the grease around not between the contacts. Hard to do on a relay by the way.
Dielectric grease works fine( applied lightly) can't understand for the life of me why they insist on packing electrical components with lithium grease. Obviously because its cheaper. Maybe they should charge $100 more and use good relays and dielectric grease instead. There's a thought 🙄 good video 👍
Yes it’s insulating. The grease is displaced mechanically when the spade goes into the connector. If you think about it, if it didn’t no Enfield would operate from day one if that weren’t the case. Lots of anecdotes about relays and grease and many change them but it isn’t clear what the causes of these intermittent problems are nor how common they really are. Also reported issues with ignition switch, roll over sensor, ECU mapping (euro 5 only, side stand switches etc. all of these can cause the same symptoms
My issue is that after about an hour of riding the Interceptor the fueling seems to get jerky. It doesn’t stall the bike, and it idles fine, but when I start to roll on the throttle it almost acts and sounds as though it’s running out of gas. It doesn’t show any warning lights, and I can throttle through it if I try hard enough. I can’t imagine it’s good for the engine though. Once it cools and I take it back out it runs perfectly again. I’ve had the bike since May and put just over 2000 miles on it, with this problem first popping up about a month ago. On short trips around town there are no issues whatsoever. It always seems to be around the hour mark of longer rides, although only about 80% of the time. Does this sound like it could be a relay issue? I swapped the plugs for NGK Iridium ones hoping it was that easy, and I’ve been trying premium gas, but no luck so far. I’ll try anything before taking it to the dealer. I’ve tried some of the forums but people don’t respond to problems concerning their beloved Royal Enfield. I would appreciate any feedback you could give.
@@WildlifeMoto thanks, I probably will end up doing that. You mentioned in your video that you thought maybe it got worse as it heated up. I actually ordered the Bosch relays last night and will try that first, since from what I’ve seen if they aren’t causing problems yet they probably will down the line.
Olá amigo, algum desses relés pode impedir a moto de ligar? A minha aciona a bomba de combustível, o arranque gira, mas a moto não pega, não funciona...😢
