Hello all,

The bike (2010 XT660Z) cut out totally the other day. On trying to restart, the instruments and instrument lights blink on and off as though there is a loose connection, there's a screeching noise from the starter cut-off/fuel pump relay unit and you can hear one of the relays clicking on and off.

Removing the relay removes the problem with the instruments/instrument lights but obviously the bike won't start without the relay.

Replacing the relay unit seems the obvious option here (the bike has 60k hard miles on it) however looking at the male plug that goes into it, there is a loose earth wire in addition to the one already in the plug. There should only be one earth wire, so I'm at a bit of loss about what this second one is doing here and whether this has anything to do with the problem.

Any ideas?

Photos below, along with a video of the original problem as described here.

Photo of spare earth wire
Photo of relay wiring chart

Thanks in advance

Ed