Where does this go . . . ???

[daveson]

True, it's unlikely but a quicker test than dismantling the starter. An even quicker test, when the engine starts but the lights remain off after releasing the start button, push the start button a number of times. If the lights then come on, that's looking like Laitch's path is the one to follow, if there's no change with the earth jumper test.

Unlike a lot of bikes, it's OK with a brick to push the start button when the engine is already running.

[Snowman]

I have no lights or horn even before starting the bike. Normally after first turning the key the lights come on. I have no lights before or after starting the engine.

[Laitch]

I have no lights or horn even before starting the bike. . . . working through the problem, I'm not looking for an electrical fire.

You seem to have your priorites correct, Snowman.  frankenduck has already indicated your choices. Either the load shed relay is faulty or the ignition switch or the wiring somewhere from the ignition switch to the load shed relay is faulty. Based on your description so far, there seems to be power to the load shed relay but it isn't being relayed to the headlights and etc. when the ignition switch is turned On before the starter button is pushed. With the relay on the bench and with your tongue not touching any of the terminals, does the blasted relay click if 12V is connected to its terminal 30 and either 85 or 86 is grounded? I have a feeling you're starting to love this. 

[frankenduck]

Do you have a multimeter?

Checking the 85 and 86 terminals of the load shed relay socket as I described on the prior page will help you determine why the load shed relay is not engaging.

[frankenduck]

You seem to have your priorites correct, Snowman.  frankenduck has already indicated your choices. Either the load shed relay is faulty or the ignition switch or the wiring somewhere from the ignition switch to the load shed relay is faulty. Based on your description so far, there seems to be power to the load shed relay but it isn't being relayed to the headlights and etc. when the ignition switch is turned On before the starter button is pushed. With the relay on the bench and with your tongue not touching any of the terminals, does the blasted relay click if 12V is connected to its terminal 30 and either 85 or 86 is grounded? I have a feeling you're starting to love this. 

An easy way to test those small black relays is with a 9V battery touching the 85 and 86 terminals.  You should hear a very audible click when you put the 9V battery to 85 and 86. They're not polarized so + and - don't matter.

[Snowman]

Some updates:
Putting a 9V battery accross terminals 85 & 86 I do get an audble 'click'.
I do get 12v on 86 with the load shed relay removed and the ignition turned on. I also have good continuuity between terminal 85 and ground.

[Snowman]

Update#2
I put everything back together knowing I wouldn't be able to work on it for a few days and now everything works as it should. .
  HA! where did I put the Johnnie Walker Black? . . . .

[Laitch]

 

[Snowman]

While I am happy at the outcome, where did that bastard gremlin go? I will ride and see, I have a 700 mile round trip the weekend which should be a good test.

[daveson]

Maybe pushing the relay in and out cleaned up a susso contact.

It would probably be good to clean and spray some deoxit on the relays, sockets and wiring plugs.

[Snowman]

Well, my gremlin is back. The 'fix', whatever it was, was short lived as I am back to square one; no lights/horn after turning the key on and no lights/horn after the engine starts. I am going back to the beginning of this thread, read it again and start over.

[rbm]

Check the relay socket and see if you can reform the female contacts so that they make better contact with the relay's male tabs.  It sure sounds like an intermittent contact problem since it worked when you reseated the relay then suddenly stopped.  What you can do is use a flat blade jeweller's screwdriver levering between the contact housing and the contact to close the gap on the connector.

[Snowman]

We alike. I will do that first, for it to stop and start working I do believe it is a connection issue. Thanks!.