Yesterday I wired in a new starter relay. I crimped the new connectors with the correct diode. I pulled the Shorai from fridge and tested with just the main and starter circuit fuses installed, I pressed starter and she cranked. Put airbox back on and installed Yuasa battery. Hit starter: no crank but neutral and oil light lit on dash. Today I pulled airbox back off and tickled wiring harness: tested w/same result. I tried jumping the two connectors on relay also with same result: no crank/dash lights on. I put old relay back in and tried jumping that: same.
Both batteries and starter purchased new last year. I inspected the wires and all I could find was the negative battery cable was nicked. I was having a problem with several main fuses melting due to looseness but cured that in July. Also when leaving the ignition ON the coil was very warm but I am guessing that is not an issue. My only idea is a short within the fuse box or between battery and relay. Any suggestion appreciated. Jerry
A nicked ground wire will not short anything. Try a known, good battery.
I hooked the Shorai negative to bike and touched the positive to the starter cable. Same result:dash lights and no crank. I could not find anything wrong with starter cable but terminal on starter was filthy. I will push bike home tomorrow and clean and test.
Today I cleaned starter terminal and tested: same result, I jumped it directly from battery to starter terminal: same, then I put negative on engine: starter motor cranked. I tried grounding the test circuit to other negative cable under the battery (which goes into main harness) same result dash lights w/o crank. Earth fault correct? Both sensors connected to engine lighting up.
EDIT: I finally found it. I looked over the wiring chart and saw that the negative goes directly to regulator. Moved the wires around regulator and got her to crank. Probably when moving the ignition switch around I caused the fault.