It is definitely the relay. To troubleshoot this once and for all, I did the following:CWH wrote:Dwayne,
I could understand the problem being a relay fault if the contacts failed to close when the relay coil is first energised, this is indeed a common symptom of relay failure. If the energising coil closes the contacts it would be unusual for the contacts to drop out, but then close again because you tap it! It could however be a wiring fault to the relay (check the connections to the relay socket) as tapping it, or pulling the relay out and pushing it back in, may move things enough to close a broken wire in the wiring loom or relay/fuse box.
If I tap the Motronic relay with the fusebox cover door a few times, the fuel pump cycles every few taps (fuel pump relay and motronic relay are connected in series), I then changed the fuel pump relay with the Motronic relay (that’s the relay I have identified as having a fault), then tapped the (Fuel Pump) relay that was now located in the Motronic relays slot, and it didn’t effect the fuel pump one bit. Tapped a few more times, still no effect. Then I put the suspect (Motronic) relay back in its native slot, tapped it, and the fuel pump comes on every few taps. Therefore it is not the connection to the relay ports, but (Motronic) relay itself. I have now swapped the Motronic relay for the horn relay as they both have the same part number.
I’m not too concerned as the bike goes in on Tuesday to get the 1000k service done.
Finally, I have this problem sorted.
Thanks to all that posted links and gave encouragement.
