Kiwi_Roy Posted April 20, 2010 Posted April 20, 2010 What I did next was bend the spade terminals of both relays out slightly so that they would apply pressure to the mating contacts in the relay bases. I successfully started the bike up again and wiggled the relays. No coughing or spluttering. It appears I’ve fixed the problem as I’ve ridden the bike to work for 2 days now with no ignition problems whatsoever. It's possible to replace the connectors in the relay bases, they are a standard item in a good automotive parts provider. There are two different sizes in the base. I get the connectors out by releasing them from the top with a pop rivet nail filed to a chisel shape. I suspect relay 5 is subject to very high short term currents (average will be much lower) as the injectors fire, any resistance at all will prevent them firing properly. As well as the injectors, 2 coils and pump. If it happens again try placing a jumper from one of the other fuses right across to a handy point in the injector, coil, pump wire thus shorting across relay 5 to see if that cures it. Regards Roy
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