Nailed the bugger.
Since the issue was low voltage at the key switch, I traced the wiring back to the fusebox, where I measured
13 Ohms between the 2 points. That would certainly give me the voltage drop I saw.
I suspected a bad joint, and wriggling the wires behind the front panel revealed nothing.
Then I moved further back in the loom, and when pushing it hard against the frame just ahead
of where is exits the plastic guide inside the frame, I saw the conditions change.
That pointed to an issue in the loom bundle.
I stripped the front binacle off and freed up the loom up to where it entered the inside of the
frame (pic1), and removed the cloth tape. Then I moved further back and removed the fibreglass
tape, and saw the issue (pic2). The red wire was chaffed, but not right through the insulation.
It did however look suspect, and when I bent it, I noticed it was broken inside. I pulled either
side of the chafe, and it came apart (pic3). Although it hadnt worn through, teh insulation had been
compromised enough to allow water in , which corroded the copper, which was evident from the green
verdigris. Fortunately that particular wire splits into two and was a bit longer than the others. This allowed
me to cut out the corroded bit, solder it together, add two layers of heat shrink and some insulation tape.
Wrapped the loom up, plugged everything in, and she fired up fist time.....success.
Tomorrow I will re-assemble and be thankful for the "easy" find.
Pic1.jpg
Pic2.jpgpic3.jpg