A couple of times there you've mentioned getting a small spark at the plugs when turning on the ignition.
Just to be clear .. you are saying that happens without pressing the starter, aren't you ?
That seems odd to me.
Though electrics isn't really my best subject.
As an aside, its interesting what you say about switching off at the kill switch to prevent sparking at the main relay, Flip.
For some reason, dunno exactly why, I always switch off at the kill switch.
Maybe some half-remembered advice from the dim and distant.
Anyway, after 17yrs I'm still on the original relay and have never had any problems with it.
Seems to support your theory.
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