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Ground.
You will avoid many electrical problems by making sure of good grounds. The alternator puts out about 35 volts, AC. The rectifier converts the AC to DC, at a nominal 12 volts. Actually, 13.1 to 14. If that rectifier is not 100% grounded, things like CDI's are trying to handle short spikes of too much AC voltage that they were never designed to deal with. The frames come down the line painted to where the parts are attached. I have previously stated what it is like working on an assembly line. You only have so much time at each station to bolt these parts on. I don't know of an assembly plant anywhere in the world that does not use air operated torque wrenches. Some are magazine fed, but most are not. The theory is that the screw attaching it to the frame will cut through the paint in the hole and make an acceptable ground. I'd say 90 or 95% of the time it works, maybe even more that that. But if you count the number of grounds on your bike, even 1 % means that about 1 in 25 will have problems. Could they ream out the holes to ensure good grounds? On a $1200.00 motorcycle? Get real...ARH
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