load shed relay going crazy

[PsychoRallye]

Hi guys-
Posted on this a few months ago on another forum but never followed up.. and never got very far anyway.

First: unmolested 85 K100.. low miles, under 40k, basic model no fairings, bells or whistles.

When ign is on (key turned 90 deg) the load shed relay clicks so fast you can hardly hear it switching.  The bike does not start and nothing electrical works. No fuel pump or lights, for example.  If I push the starter it f does not crank but the LSR clicking gets louder.

Battery good
Relay good

If I remove the bulb monitor unit the clicking in the LSR stops.
If I bypass the BMU with jumpers the clicking comes back as if the real BMU was there.. so I don't believe it's the BMU.
If I disconnect the headlight, front signals or all the rear lights no change, it still clicks.

If I disconnect the starter, no change, it still clicks.
If I disconnect the ground on the frame backbone just in front of the fuse/relay box it stops clicking.
Tried dissembling the key/ ignition switch and cleaned it no change.  Same with the starter button.

L ooking for ideas... can't get this beauty running!
Thanks for any ideas...

[wmax351]

Clean the starter motor brushes and commutator. Its grounded through the starter motor.

[frankenduck]

What happens if you try to start it with the load shed relay removed?

Have you checked/replaced all of the fuses?

FYI: The fuel pump doesn't run unless the engine is turning.

[kioolt]

I don't believe your load shed relay is your problem.  The load shed relay will not keep the bike from starting or from running.  The load shed relay's soul purpose is to cut UNCESSARY load from the battery while starting.  Since the ignition system, fuel injection system, and fuel pump are needed for running as well as starting I believe you can forget about the load shed relay. 

[frankenduck]

The load shed relay is triggered by the starter relay.  If it's clicking and the starter motor isn't turning then one possibility is that something is amiss in the starter relay and you're not getting adequate power from the starter relay.  One way to test the starter relay would be to put 12V+ to the black/yellow wire.  That's the trigger wire for the starter relay from the start button.

[PsychoRallye]

Good idea on the starter bypass, I'll try that this coming weekend...

The bike does not start with the load shed removed.  I have the starter out now, I replaced the one brush that is attached to the stud that the wire goes to (just happened to have that one new in a bag), but the other one doesn't look "too bad" (the brush that's attached to a plate). I cleaned the commutator and I'll try to put the re-assembled starter in this weekend... fingers crossed!  I assume I should clean the case of the starter on the contact points it makes with the chassis and the complementary chassis points too, since I presume those are where it is grounding?

One silly question, I noticed the grease seal at the front of the starter that the shaft rotates "through" (not any of the o-rings) is kind of worn, though not badly, but it is brittle.  I tried to find a place that sold a replacement, but no dice.  It's also not on the parts fiche.  Any ideas?  Or is it completely irrelevant and I should just not worry about it.  I had replacement o-rings and those are already on.

Checked all the fuses, by the way.  They all seem ok.  I can try replacing them when I find my bag of fuses around here...

Justin