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[special_K]

Seconding thanks for jefrs' very helpful reply. Had a second (more thorough) look over the bike and checked all the connections. Found a pin to one of the relays that had come loose, bike now running as normal.

Moral of the story for anyone coming across this thread with similar problems - even if you think you've checked all the basic stuff, check again before you start throwing parts at the bike!

[IanC]

Try the spark plug cap. The Indian metal ones allow current to track through the body, weakening and fragmenting the spark. Recommend a plastic replacement.

[jefrs]

Ah yes, my indian spark plug cap fell off the HT lead and when I tried to fix it back on the cap fell apart in my hands. Binned. There's a little screw in a HT cap, the cable has to be screwed in not pushed in. As it had fallen apart I inspected the HT cap shaped object, no screw, doh!