Denali Mini Sound Bomb Question - MYSTERY SOLVED
The light bulb came on when I realized the random intermittent honking only happened when I was riding the bike, ie sitting on the seat.
I'd placed the relay right next to the CDI box, which is a little shorter than the relay. One of the plastic prongs on the seat pan was contacting the relay and, when I got on the bike, my fat ass was making the relay short out internally. I could see a little scuff on its outside.
So I moved it over next to the (much taller) intake snorkel. Problem solved.
I've chased down some truly weird electrical issues in my time, but this was a first.
Administrator, if you want to leave this as a cautionary tale for anyone else doing a relay-included install, please do. But you won't bother me if you want to take it down.
Mush on.
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