Your description makes complete sense, thanks very much. The details you provided are very helpful.
Based on what you are seeing, the first thing I would check is the bonus score relay (I relay). On this relay, there are five switches. Two are NO (normally open), two are NC (normally closed), and one is make-break. I suspect that the NO switch that is the lock-in for the I relay is out of adjustment and is always making contact. One side of this switch has a yellow+black wire. The other side of this switch (with a slate+black wire) is connected to one side of the I relay coil.
According to the schematic, if the above switch is always closed, then the I relay will pull in as soon as the bonus scanning operation starts (that is, as soon as the ball enters the outhole).
The score motor on your game always provides a series of 5 pulses for scoring during each score motor cycle. For example, to score 500 points, this 5-pulse train would cause the 100 point score unit to step 5 times. The circuitry of the score motor can be wired so that a component will only receive specific pulses, rather than all 5.
The I relay being pulled in will cause you to get 1000 score during the 1st pulse of each score motor cycle, even though there are no pool balls down. Also, when the I relay is pulled in, the 4th score motor pulse will step up the bonus unit one time.
The I relay is forced to drop out just prior to the 5th score motor pulse, due to a motor 3C switch. That will allow the 5th score motor pulse to also step the bonus unit one time, which would explain why you are seeing two bonus unit steps per score motor cycle.
Note that when real bonus score is happening, the 5th pulse to the bonus stepper is disabled by a switch on the bonus score control relay (J relay). The J relay pulls in when the bonus unit scanner finds a lit pool ball. This would explain why the bonus scoring is working as expected when all the pool balls are lit, because in that case, the J relay is pulling for in every score motor cycle of the bonus count, which makes the I relay seem like it's behaving correctly.
Of course, the above is just an educated guess. The bonus counting logic on this game is fairly complicated. But, as far as I can tell, a stuck lock-in switch on the I relay would be a good fit for the specific symptoms you are seeing.
- TimMe