I hope you have good breakdown cover... If wiggling the fuse had restored power, I would agree that there's not too much to worry about. However, for removing a fuse to restore power is pretty damned weird. When it comes to electrical weirdness, my thoughts would turn to earthing. Have you removed, cleaned and tightened the main earth? Also, the ECU earth has a reputation for causing weirdness. Got some new relays yet??
Totally understand and wouldn’t expect you too touch anything now it’s working but for peace of mind in the future it would be worth confirming that the fuse in question is item 13 (I believe it is) and then establishing that it is wired as per the diagram as if it is then something is wrong.
As per my posts, I have confirmed the fuse is for the charging system and only that. I would not be surprised to find that a diode in the rectifier is failing. That may well explain why pulling the fuse has allowed the ignition to cycle properly. Bike is operational and waiting for a damn good weekend thrashing while I work on getting my Multi ready for upcoming longhaul shenanigans!
Yep definately some weirdness going on! Checked all main connections early on to confirm it was not that. Followed by evry plug on the main loom, more for a visual than anything else... Funny thing is, I have just finished doing similar to my Multi, putting HD cable kit in, such is my life! But I have not done ecu earth, and I am also very happy it was not the ecu itself crapping out!
Don't know if this is now cured but, if not, I had a very similar problem on my Aprilia RSVR. Ignition would sometimes fail to turn on, sometimes OK. LOTS of delving in to electrical components, fuses, battery connections failed to solve it. Frustration and exasperation set in and I started cutting the tape off the ignition switch loom and tracing each wire. One wire I traced back to a plug-in relay where I found a contact that was not 'clicked' in place. Turned out the loom would move with steering head movement and the contact was sometimes getting pulled back slightly from the relay base. Clicked pin in, no more problems. The bike had never been apart, all was original so pin must have not been correctly seated at build. Worth checking if still on-going.
Ok, so further to this, it was still happening and on lifting the tank and wiggling the mini relays and the 40A fuse, it would always eventually cycle up. Frustrating, but not the worst I have dealt with. However last weekend I had a fuel line blow out and fortunately my mate noticed the petrol so I got trailered home. I replaced all fuel lines and also the mini fuses, as per Old Riders suggestion and have had no issue on the big ride I did yesterday. Hope that is the end of it, although I am now left wondering how to get the horrible petrol staining off my engine side covers... Such a fun bike to ride!
@PaulPhillips I had an 04 S4R and an 07 S2R and I`m sure the later bike had the updated loom so an 08 bike should be fine. Just watch out the plastic tank has not swollen on a bike that age. The earlier ones had steel tanks.
