Have you disassembled, cleaned and reassembled the little bonus stepper that's mounted on the underside of the playfield (I don't have a Royal Flush in front of me, but is it labeled "I"?)? If you're having intermittent problems, I'd guess it's probably a mechanical problem. Cleaning that unit, and the copper contacts on both sides of it so that's moving with a crisp click each time the solenoid fires may help. It has a bunch of wires, but detaches from the playfield with a single Jones plug, so you can take it to a bench somewhere with good lighting and take it apart for cleaning.

Did you check the BX? They're tetchy.

BX is last ball relay.

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Hi newovad
the Bonus-Feature in Royal Flush is complicated. I have some questions to Your post-1: Sometimes it works means Single Bonus always is O.K. (besides maybe skipping a position) ?
Sometimes it works means Double Bonus sometimes is O.K. (besides maybe skipping a position) ?
Sometimes it sticks and gives quad bonus means when You have quad bonus You have the whole bonus feature quad ?
Do You sometimes have triple bonus ? Do You sometimes have 5 or 6 ... times faulty bonus ?
In the first JPG in post-1 I see "J (Relay) has ONLY ONE Normally closed switch (text: AS. 1A)" Please look in Your pin - is this true - the J-Relay ONLY has ONE switch ?

Here https://pinside.com/pinball/forum/topic/card-whizroyal-flush-bonus-question#post-3983173 there was a problem with the 1000ds Bonus - but not a problem with quad bonus --- do not read there. I show here the functioning single Bonus - how to get 1000 - 2000 - 3000 - 4000 - 5000 points. In this I do not see a chance to do for "double bonus" a quickly actuating once more the L-1000-Relay so to me means "double bonus" is done by resting double time in a given position - giving single bonus and again single bonus. (Thats why I was asking for "faulty triple bonus ...")

Frankly - I do not see how the stepping through the bonus-positions can be slow-downed - the switch "J" in the last JPG in post-1 (shown in the middle between Your yellow mark) gives me headaches - I want to be sure about " the J-Relay ONLY has ONE switch" - if true I then must brood about this place in the schematics - if false I must search in the schematics for drawing of J-Relay-Switches. Greetings Rolf

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Give the whole relay a good look.

Hi Impact93
thanks for Your answers --- the single bonus fully works. You may think about "I want to play, play, play - for a while I make it impossible for the KX-Relay to actuate - I play all games - all balls simply 'single bonus' ". See the schematics at "D-7" the coil is fed by 6VAC - one side of the coil has (probably) two wires-color-BLK-WH soldered-on. The other side of the coil has soldered-on wire-BLK-YEL leading to a switch mounted on the relay. Unsolder wire-BLK-YEL away from the Coil and You will have always single bonus - OR SIMPLY unplug the Adj-Jack "3 Balls - 5 Balls" and do not plug-in.

Your example "stuck at (single) 2000" - would be interesting if You (when faulty) always get 4000 or sometimes 6000 or 8000 points. Also would be interesting when You have lighted the 1000, 2000, 3000 - doubled: When faulty You have ALL doubled ?

Interesting is Your description on behaviour of J-Relay: Non-pulling - pulling - reopens. Also of value: ONLY one switch on the J-Relay - the problem seems to be "Why is it not pulling-in after the first set of points ?". I believe the KX-Relay actuates and stays actuated when You reach "Ball-2" - correct ?

I must brood over the last JPG in Your post-1 - by now I do not see the Non-pulling - pulling - reopens. Greetings Rolf

Did you clean the switches on it? (not just the board and contacts)

Hi Impact93
see the JPG - "encircled red" - one of the many switches on O-Ball-Return-Relay --- I believe this switch is tight - sometimes faulty closed when the O-Relay is not active. Then the running motor doing its work - closing and closing its switch-1A. I believe that faulty switch on O-Relay causes the "skipping".
The second video in post-13 --- I do not hear Score-Drums - I believe to hear the Score-Motor actuating --- can You please give some explanation to the video ? (It is getting late here in Switzerland I probably will go to sleep soon) Greetings Rolf

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What is the KX relay?

Have you checked for "floating contacts" ie-the contact is just a bit loose on the blade and needs a good squeeze with some needlenose pliers? It seems like that, a bit of a short, or a semi-cold solder at this point.

Hi Impact93
I guess I got it --- Is Your J-Relay actually a ministepper with a switch alternating between open and closed ? See here http://www.pinballrebel.com/pinball/cards/cards/Used_cards/Gottlieb_AS-relay_Adjustment_B-11492.jpg every second step the switch on top is closed. I wish that Gottlieb would have written in the schematics what I have written: "alternates opened - closed". I was working / drawing the JPG then I realized "J-Relay is an AS-Relay-Ministepper".
To Your "quad bonus problem: Check / clean (maybe adjust) this only switch on the J-Relay - also check "wires truely soldered-on" ? Greetings Rolf
P.S.: I show the JPG as I was working on --- the JPG here and the JPG in post-9 covers the whole Bonus Feature.

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Hi newovad
I apologize - I did address You many times as "Impact93". One faulty writing and then copied, copied, copied ...
See the JPG - the schematics are drawn abstract - they do not show the exact wiring in the pin. Yes, electrically the schematics are true --- but wires may run other than drawn - example: In the pins there is never a fork-off from an connecting wire - always solder-lugs are used. See the bottom of the JPG - maybe the actual wiring in Your pin is as I have drawn it. Please check all the connecting wires - I-Relay, J-Relay, KX-Relay. When the pin is in Game-Over: Toggle-off, unplug the main power cord (Safety Reasons) - look at the stepper and its switch (J-Relay): Is the J-Relay in a position so the switch is open ? Greetings Rolf

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I have a somewhat similar problem where my double bonus never turns on. I assumed that for the last ball when on 3 ball, double bonus should be on.

If I manually turn on the relay KX for double bonus it works as it should, counts down and scores correctly. When starting a new game the double bonus coil “off” relay triggers correctly. But will never turn on again.

If the Double Bonus (KX) relay doesn't activate on ball 2 of a 3 ball game, Inspect and diagnose this circuit with Alligator clip jumper wires
http://www.planetimming.com/Pinball/troubleshooting/EM%20Troubleshooting.pdf
http://www.pinrepair.com/em/index3.htm#features

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Thanks HowardR, I don’t know exactly what I’ve proven. But if I run an alligator clip between BLK-YEL of KX, and YEL of Q..

The KX relay flips on, The Double Bonus lamp lights, and the ball in play “2” light is lit. Double bonus scores correctly at end of ball.

Does thus mean the issue likely resides in the player unit?

Probably but you can verify that by running your jumper between the Yellow and Brown wires on the Player unit disk.