Dave,Hi,try swapping the relay to the left of it with one of the other ones on the right side of the relay box.This is the load shed relay which switches off all consumbles when starting the bike. I assume that you have checked the obvious such as battery connections ? When the horn activates itself do the head lights still work or do they go off as well. reason i ask is that the relay uses the starter motor windings as an earth so if the starter is dodgey fault could probably lie there.have you tried bypassing the earth wire on the horn and running an independant earth wire off the horn ?