Gauges & taillights not working

[dand]

Last summer I started having intermittent problems with the OD indicator light going out on my 98 GL1500. Then on the last ride of the season, the low fuel light came on when tank wasn't low. Then the fuel and temp gauges quit working. I started troubleshooting when I got home and realized the taillights and front fairing lights weren't working along with the side stand indicator light. Fuse was good so with my repair manual, it seemed like all the problems were related to the #3 relay. Changed really with the 30 amp sold on this forum and everything working again. Put bike in storage for winter, took out for first ride this week. 20 miles into ride, low fuel light comes on for a short time and then goes off. Fuel gauge still working. 10 miles later OD light and gauges quit working again along with same lights and side stand light. Got home, replaced #3 relay, no luck. Checked #8 fuse, good. There is power coming into one side of the fuse circuit. Is there something else I'm missing before I start looking for bad grounds, loose connections? There is no corrosion present in the relay or fuse terminals.

[MikeB]

I may be wrong but it sounds to me like the terminals for the #3 relay are not be making good contact with the relay terminals.
You will probably need to tilt the relay panel out, remove the rear cover and inspect the terminals.

[dand]

I cleaned up the ground above the oil dip stick. A little corrosion, but not that much. Tried it again with no change, but then I wiggled the relay and everything came on. It stays on, but if I wiggle it side to side everything goes out again. Looking at the relay terminals from the front, it appears that one of the four has a wider gap which may allow for the movement. I'm going to narrow the gap by bending it with a small blade screwdriver before I take the relay box out

[dand]

This is the suspected ground. To keep it from rusting again should I repaint around the frame and ground screw?

[MikeB]

You could add some paint or some Extend Rust Neutralizer made by Loctite. Applying it will turn rust black and stop it cold.

[dand]

Thanks for the help. If it starts acting up again I'll pull the relay box and check out the terminal