Well evidently there may be an internal short that happens when the relay is bolted-down, so sounds-like you need a relay. Maybe part of the internal circuit board/connections distorts-enough to allow the short to occur. I don't think you want an electrical short potential on your bike, as you could come-out & find it caught fire. One of my friends had a Kawi Concours starting circuit w/a similar issue, coupled w/a leaky fuel petcock, cost him his barn in Scottsville NY. :confused2:He was a child phenom, raced for the Bultaco factory in Europe in the '60's & had a Kawasaki dealership in Rochester NY at one point. His parents were British and Spanish bike dealers in the 1960's, on Ridge Rd. They had a scrambles track behind the dealership on their acreage. A great place to hang-out if you were into bikes. His older brother was a national ice racing champ not long-ago, they're friends of Jay Springsteen. I used to run-into them at Daytona.
