85 550L:Won't Fire(start), Grinds slowly when Cranking

[trickyarcher]

Hopefully the title was full of information, but I'll elaborate.
Bike: 1985 GS 550L with 14k miles.

When I turn the key, all the lights come on, high-beam works, turn signals come on.

Problem1: When trying to start the bike (press the start button), I get a click and the (+) battery cable gets hot enough to melt the rubber cap. I used a precision screwdriver to connect the cable to the battery (out of laziness) and the screwdriver got hot enough to melt through the battery terminal.


Problem 2: Got the battery charged up and screwed the cables on tightly. When I press the start button, the starter sounds like it's grinding and the lights go dim, but it doesn't sound like I'm getting any spark to the combustion chamber.

Eventually, the battery drains and I just get a click and then nothing.

Checked the fuses: they are good.
Pulled the cover off the wiring harness: I can't see anything bad, but you never know. .
Pulled the connections from the Horns in case they were shorting. . .
And I ran through many of the checks in this thread:

http://www.thegsresources.com/_forum/printthread.php?t=69052&pp=10&page=3

There is a good mechanic here in Alexandria, VA, but I'll have to tow it and I don't know when it will come back ready.

I would like to know what needs to be done before I drag it in there for unknown electrical work and a $270 carb job.

Thanks,
Damien

[Dave8338]

Make sure that all your ground connections are CLEAN and use some dielectric grease on them when you put things back together. Is this problem something that just started and has it worked well in the past? If it is not a connection issue, you may be looking at tearing into the starter.

[trickyarcher]

Make sure that all your ground connections are CLEAN and use some dielectric grease on them when you put things back together. Is this problem something that just started and has it worked well in the past? If it is not a connection issue, you may be looking at tearing into the starter.

There was a bad rainy October last year that pummelled my bike and it hasn't been the same since.

It ran ok before hand. Needed a carb job, but it ran fine.

[fgh]

That kind of heat at your battery indicates a short or an overload. Since you say the starter is GRINDING that would indicate a problem in the starter or starter clutch.

[aosmith]

yup my money would be on a short internal to the starter

[chef1366]

Clean the ground connections from battery and crankcase and use dielectric grease. Do the same with the positive side of battery and both ends of the solenoid and the starter itself. Use a fine grade sandpaper. If the starter needs rebuilt try here for parts. http://www.stockers.com/

If it's your starter clutch try Ebay for a used one. My bets on the starter itself but a bad ground will create the heat that you are experiencing.

[trickyarcher]

Guys,
Thanks for all the help. I will try to apply everything you guys have said. . .just as soon as the locksmith comes by and replaces my broken key.

I'll keep you posted so that this information can be used for future diagnosis.

Damien

[relic-rider]

The starter on my 1000GL has been giving me grief lately. I cleaned the contact button in the right handle switch and that seemed to help. But yesterday when I removed the starter cover to get access to the stator wires , I found this.





It appears that the wire had rubbed through where it went through the starter cavity and was grounding out on the engine case. Every time you hit the starter, the cable between the cut and the end got real hot. The rubber cover melted into a glob and the wire turned hard as a rock.