Ignition Switch Issue Revisited?
I've had an 04 ABS since new and in the past I was a regular poster in FJR forums. A few years ago. I stopped riding - but with 2 new knees I'm back - and I have a question. Please excuse my posting this on 2 forum sites - my forum memberships had lapsed so I joined them again today as a new member.
Ok, the ignition switch question: back in maybe '07 my key switch had acted up, sometimes not making good contact. At the time there was a forum member who was selling a wired relay that solved it by plugging into the switch harness to carry the current better. I got one, put it in, and it has worked fine for years. The part tag says Ersatz Electric s/n 012908-028. Does anybody remember this member's name or how to contact him? I have a new issue now and figured he'd be a good person to consult about it.
Getting the bike ready to ride again, I put in a new battery. Things were fine at first, but sometimes turning the key on does nothing again like 10+ years ago. The next time its fine, full strength, everything lights up, starter cranks and it starts right away. But its inconsistent.
I remembered installing the add-on helper relay downstream of the key switch - so I checked it for continuity, clean contacts, functioning relay, all good - it still looks new. I even tried a different known-good key switch I had bought years ago - acted the same - totally dead sometimes. Cleaned the battery terminals (again), still dead one time in 3 or 4. Or sometimes it will be dead on 6 or 7 attempts, then start working fine, and be good for several more cycles.
As if this isn't confusing enough, now comes the real head scratcher. With the add-on helper relay taken out of the circuit, and the switch wires (tan and red) plugged in directly as they were originally, it now responds perfectly every time I turn the key on. The trouble is I don't trust it.
Sorry for the long post - and sorry for doubling up if you visit both FJR sites. Hope somebody has some ideas.