R100GSPD relay issues

[SeattleAirhead]

I am having a strange issue that I hope someone here can help me resolve.
My GS isn't starting - I have isolated the issue to something related to the relays - what is happening is that when I turn on the key, I have all lights, but no ignition when I press the start button. I checked the switch, and it looks and tests fine, so I looked at the battery and connections both good. I checked the relays, and when I pull the Schleisser relay (two small black relays next to the starter relay) I lose lights (as expected) but now have a properly functioning, crisp ignition! When I plug the Schleisser relay back in, I have lights, but again no ignition. What gives?! I ordered new relays and replaced all three - no difference.

I'm stumped, and was planning a ride in two days! ANY HELP WILL BE APPRECIATED!

[dwerbil]

Welcome to the forum, Seattleairhead.
To help things along, you should include the year of your GS.

[SeattleAirhead]

Ah! Yeah, I guess that'd help! It's a '94 GSPD.

[dwerbil]

Message bump

[Deleted User 62]

I had similar problems when working on a friends '92 GS, new relays didn't fix the problem, but when I wiggled the wires going to them it worked. It turned out the plugs connected to the relays were not making good contact. Age, vibration, and weather had made the plugs connectors too loose. I had to pinch each of the metal tubes of the plugs contacts slightly to make it work. Edited to add: I also changed the pos and neg battery cables at the time, as they were well past their useful life. I'm not even going to mention the PO's wiring hack job to add an aftermarket instrument cluster with 30+ crimp connectors inside a ball of electrical tape, or maybe I just did!

[SeattleAirhead]

I will check the wires - it makes sense that it is something loose. I pulled the Schliesser rely and as previously mention, the bike started right up, but of course had no lights, I then pushed the Schliesser relay back in and the bike continued to run and I had lights! Whoo hoo! I shut it down, and restarted it with lights and normally strong start - so I was hopeful! I took it for a short ride in the neighborhood and it pulled up the hill as if all was well, then the battery light lit. I turned around and came home. Man I hate electrical crap.

[Major Softie]

Man I hate electrical crap.

ESPECIALLY intermittent electrical crap!

[jagarra]

I had a similar problem on one of my previous motorcycles. Turned out to be corrosion not on the contact where it meet the relay, but corrosion on the wire where the crimp was made to attach to the contact that is inserted into the relay block. You sometimes cannot see it as it will be hidden by the insulation, I have seen it go back down into a far piece. Try taking measurements to see if you see any higher than normal ohms readings on your power wires going to the relay blocks. The problem is they usually affect the amount of current that will pass through the connection.