92KK 84WW Olaf
Life time member
Number of posts : 7955
The relay would seem to be getting power the moment the ignition is turned on. Check the incoming supply wire to the relay, if it's live the moment the ignition is on then the problem is further back. If not then it would seem to be the relay itself. A simple disconnection might show this one up.
Work back from that with the first one being the connector from the handlebar controls to the loom, just checking with ignition on and off. If opening that connector does not stop the problem then it's somewhere between the connector and the starter relay.
If that does solve the problem then it would seem to be between the loom connection and the handlebar controls. Its not easy to open up that one but it can be done.
If you trace the wire back you may find a short somewhere. There are a few potential pinch points that if the cables are crushed could become problematic. In extreme cold the insulation becomes brittle and moving a bike around in freezing temperatures using full lock is hard on the insulation.
I was in under the tank in my LT and there were what appeared to be some same coloured wires and identical connectors but that were not designed to go together. I am wondering could one of these have become an issue after changing the clutch switch..?
Also in the back of my mind is the routing from the start button to the ECU, its one of two feeds to the ECU and which should only work when the start button is pressed. I don't have the answer to this one but someone else might: if there is a fault here could it affect the starter relay? The other being the Hall sensor, this one appears to be in order.
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1992 K100LT 0193214 Bertha Blue 101,000 miles
1984 K100RT 0022575 Brutus Baja Red 578 bought 36,000 now 89,150 miles
1997 K1100LT 0188024 Wotan Mystic Red 689 58,645 now 106,950 miles Deceased.
1983 K100RS 0011157 Fricka 606 Alaska Blue 29,495 miles Damn K Pox Its a Bat outta Hell Now 58,200 miles.
1996 K1100LT 0233004 Lohengrin Mystic Red 38,000 miles currently 51,800 miles.
1983 K100RS 0004449 Odette R100 colours 58,000 miles. Sprint fairing now 63,390 miles
Past:
1968 Yamaha 80 YG1
1971 Yamaha 125 YAS-1
1968 Honda 125 SS
1970 Honda CD 175
1973 Honda CB500-4
Honda CX 500