Electric problem, not one but two

[kokis]

Hi guys,
2 weeks ago I took my monster 696 from garage where it was stored for couple months being started every 1-2 weeks to keep battery alive. When I took it back first start was with problems. Pump did not started. I restarted bike and pump started, but starter did not worked. I restarted again and it seems to solved issue and engine started. I had same issue with starter once or twice last year.
So I took monster and dropped it to mechanic to service it.
New clutch plates, slip-on and some other cosmetics.
Also new lithium "performance" battery, rizoma turn signals front and back, rizoma short tail with it's own license plate light, rizoma foot controls, PIA horn  and bikemaster HID for Hi and Low beams.
When all items were set bike wouldn't start. Pump works but no starter.
Low beam was working but Hi beam not. Middle bulb and license plate light were working. We tried to wire old battery to new one and try to start - no luck. Then we tried to connect car battery and start - no luck. After dozens of restarts CHANGE ENGINE light poped up and dash showed error HI BATT. We checked voltage and it was 11.7V. Starting starter cause bike shut down. We took of battery and set it to charger.
Well, I assumed it was HIDs because I heard some bikes\cars require HID canceler\decoder because I heard that some car's ECU\dashboard reads signal from bulb and detects HID like broken halogen bulb and prevents engine to start.
We installed canceler and also I find out that turn signals installed with only one resistor(or whatever is it, came in complect with turn lights) instead of two. This was corrected also. Inserted old battery. And engine started. While new battery was charging we finished installing headlights et.c.
We were going to set gas tank back, when discovered that stop signal is not working. Rear and front stop levers don't change lightning. Rear light is constantly red. And there are no license plate light and middle headlight.
I assumed to start engine and check if stop signal works only when engine works, because I forgot how stop and static lights look like on my bike. But engine would not start! Starter is not working!
We checked fuses in the box they all ok. Fuses that stays close to relay are ok also. Relay is clicking at button press. I was pressing start randomly while mechanic was touching relay, starter and some other points, and bike started.
Mechanic assumed that contacts on starter are corrosed and he cleaned it. Bike would not start. Mechanic attempted to close circuit(with piece of wire) on relay and starter was attempting to work. So he assumed that relay is dead and not sending electricity to starter...
While he was checking rear break pedal for stop light button issue I turned on bike and started it without a problem. I tried to do it again and again and it starts with no problem, like nothing bad happened before.

Questions:
If relay dies, it dies permanently or works\don't works like mine?
Mechaninc assumed that license plate light is not working because middle headlight bulb died. Are they on one line?
Stop signal - is it red or white? Why is it permanently red?
HIDs - does 696 require canceler\capacitor? I've got clustermake the beast with two backs of wires under frame now.
If relay is ok, where should we seek for issue?
If immobiliser\key antenna fail will relay close circuit start starter?(got to check if immobo is not issue)

Sorry for my English.

[Howie]

From what I can tell your mechanic is not a mechanic.  Find someone new.

[kokis]

He is good mechanic and wrench-guy. But he messed up some electrics.

Reading tech manual and deep forum search pointed me to these steps which I will follow:

Starting problem - Check all starting chain contacts. Check ground\frame connection. Check Kill switch contact.
Brake light - check brake button on rear and front brake manipulator
Side\plate light  - check if there is short circuit with frame\ground.
I never found on forum that someone used capacitor for HIDs. So I will take them out.

FYI "relay" in my long story is "solenoid" or starter contactor.

Fuses were fine but now I am pretty sure that if I keep bike on little more or run it - some of them will die.

Any suggestions are welcome.

[wiggsmeister]

If he messed up some of the electrical he could fry the wiring snake and it might need to be replaced.

My 2011 696 had problems with the headlight. It went out, but the high beam still worked when I used the passing light function as did all the other electrical. Initially the problem was assumed to be a connector and/or relay. They were both replaced, it functioned properly for a week, then the problem came back. The dealer ended up replacing the entire wiring snake because they didn't know why fixing the connector didn't solve the problem.

I wasn't having any problems with any other electrical or with my pump or battery, which makes me think there might be some bad/old wiring somewhere in your bike.

what's your ride & how many miles?

[memper]

Well at least if the fuse(s) get fried it will give a general indication where problems might be.

As for the brake light not working, I was working on a buddy's bike (XT 600) with the same problem. Turns out the adjuster by the foot actuator wasn't set right.

[kokis]

what's your ride & how many miles?

2009 M696 with 10.000 miles. I don't hesitate riding in the rain and I keep it at open air during summer, so I expect some corrosion there.

The dealer ended up replacing the entire wiring snake because they didn't know why fixing the connector didn't solve the problem.

Some isolation could melt somewhere under winding. Replacing was easiest way I guess if no specialist available. There are no so much voltage\power on line that  could not be fixed with proper patch cord.

Well at least if the fuse(s) get fried it will give a general indication where problems might be.

on new monster it will tell nothing

1-Key ON
2-Side lights, high/low beam
3-Consumers - wtf is that?
4-Instrument panel
5-Injection
6-ECU

Second one will just die..



Well I hope get it fixed tomorrow, will keep this threat  updated.
Thanks for input.

[kokis]

Well.

Brake light - problem was in foot control button. As it was released plate light got back ON.
Front side lamp just died and needs replacement.
Hid capacitors unistalled, Hid works fine.
Starting problem was not repeatable.. so just ended up cleaning all contacts.

Can't wait till tomorrow to get my baby back