You can clean up the contact points inside your relay, here's how. This is for a 1975 GL1000, other year models may be different, I don't know. Remove the relay from behind the battery area, disconnect your battery terminals first. Loosen and remove the two nuts on top of the relay and remove the wires. Remember where they go! Then unplug the two small wires, there should be connections just above the battery area. Remove the relay from the bike. Clean off as much grime that may be present as you can. Carefully pry open the clamp that is holding the two small wires. There will be a protective sheath around them, you need to slide that up towards the ends of the wires. Now locate and remove the two phillips screws on top of the relay. The plastic top part of the relay will then be able to separate from the lower part. The two small wires just slip through the plastic top, they may be a bit difficult to get started. The relay will now be in two sections joined by the two small wires. See the photos. You can use a dremel tool to clean up the contact areas of the copper bar. I used a small rubber wheel to do this, it will keep the contact area smooth and clean. Now remove the other nut and washers from the copper bolts on the plastic top part. Next, press out the threaded copper bolts, if you carefully cut away some of the soft rubber that is right next to the bolt threads, it will be easier. You should be able to press them out with just your hands. Do not damage the plastic top part of the relay!!! Now you will be able to clean up the contact areas of the copper bolts. I spun mine around 180 degrees when I put them back to get some fresher contact area without the deep pits. I did not need to do any work to the lower part of my relay where the plunger is, as it was working fine. So I will not offer any advice about that part. When you are happy with the contact points, just re-assemble the relay. I used a tiny amount of silicone goop around the copper bolts, you don't want any squeezing inside the relay when you tighten the nuts.
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