Here's what I learned today:
The intercom, all the radio functions, and everything for the CB work fine except driver trans.
I am using the same new helmet/J&M headset/lower cord to test from both positions.
Plugged in driver intercom, key Either
push to talk, get LOUD squeal.
Plugged into passenger intercom, key passenger push to talk, transmits clearly, no squeal.
Plugged into passenger intercom, key driver push to talk, No squeal, carrier tone, no voice transmitted.
So, I have two problems, 1) driver push to talk does not transmit from either intercom cord & 2) driver push to talk causes Loud Squeal on driver intercom only. Maybe three, as the range seems to be very limited. I have not hooked up an SWR - I assumed since the entire system is hondaline, the SWR should be calculated correctly?
Also, test with another Goldwing today. Up close our communications (both ways) using my passenger cord were amazingly clear, but when we went opposite directions, lost him quickly - very short range. I would have thought we would have be able to talk out to about 6 - 7 miles, but must have lost him at about 1, no more than 2 miles.
Removed Top Shelter again
(only 30 minutes this time
) rechecked all connections, all good, solid connections, no bent pins, etc.
Checked driver cord from red connector to 6 pin, checked okay, wired per manual, good continuty.
I think you are right, its about time to go for warranty work.