I'm with PMK on your headlights on problem with key on...Someone with a schematic may be able to identify the controller that turns the headlights on after the bike is started and go from there...I'm thinking that controller or relay may have the contacts stuck together???? JUST A GUESS...My Spyder is flashed and the engine needs to be running for the headlights to come on...Keep us updated when you find the fix...larryd