Hi everyone ,
Well here is the latest news.
The problem appears to be solved, but you would be lucky to find a solution so easily.
The remedy, This is what I did.
firstly remove all of the plastic
I inspected all of the accessible wiring and connectors for obvious signs of chafing, bad connections, overheating , etc, etc, Nothing found, everything appeared to be spicky clean and in good condition.
I back probed all available earthing points to check continuity to chassis earth. All ok, and no signs of bad connections , , both sides, and or any overheating at the connectors.Nothing found.
I checked all fuses, and relays for integrity of operation , both by substitution with a known good item and also by bench testing of the original units.
In my initial analysis of the problem it was apparent that the motor control relay (shut down relay) was holding on when the ignition switch was turned off.
However I persisted in checking all of the relays , including the start relay and then cleaning the right hand handle bar stop and run and the start switches.
The initial problem still persisted.
During this process I monitored the engine control relay activation feed from the ignition switch. The red/black wire.
With the ignition switch in the on position the voltage at the relay measured 11.6 volts
I thought that this was a little low as the battery voltage at that time was in excess if 12.6 volts.
Then I turned the ignition off and the voltage at the relay dropped slightly to 10.6 volts.Something strange here as it should have dropped to zero volts with the ignition off.
This meant that the relay was still energized and supplying full power to its dependent circuits.
On shorting the red /black wire to chassis earth there was a bit of a spark and the headlights and dash display extinguished when the relay dropped out and did not re energize.
Something strange here I thought.
The next step was to uncouple the ignition switch connector ,4 wires plug just behind the left hand fork and unplug the engine stop relay, then I checked the red /black wire for continuity, all ok there , then I checked for resistance to chassis earth , this showed a direct short , zero ohms resistance to earth, Something strange here thought I, this is not good.
A few minute later a a new substitute wiring harness was fabricated to bypass the suspected short circuit to chassis earth that the red/black wire was showing.
And when plugged into the connector for the ignition switch and the other end to the motor control relay, and the ignition switch turned on and the starter activated the motor started and ran as normal , as well as all of the dashboard functions were as normal and when the ignition was turned off the motor shut down as it should and the head lights , dash light and functions etc, operated as normal.
It seems that my problem is solved.
I will have to reassemble the bike ,(plastic's etc), and then go for a road test. just to make certain that everything is ok, but I do not think that there will be any problems now.
A half a dozen energize , start , stop , on ,of ,cycles of operation whilst on the stand and still in the garage did not show any problems when I checked all of the operational systems that I could think of, So now I have my fingers crossed.
Please wish me luck.
cheers to all,
Winston66,
Northampton , Western Australia
