Originally Posted by garry_kramer
First time tonight I had a problem, When I pushed the started button I hear a click of a relay in the headlamp housing, but the starter motor did not turn over. I pushed it down a bit of a hill at the resturant in 2nd and it started right up. I think a loose wire somewhere.
How fresh is the battery? Unless it has been replaced, the /6 has the biggest, heaviest boat-anchor of a Bosch starter under the top cover, and it draws a *huge* amount of current (of course, many will say it's greatly preferred over the later light Valeo starters that would regularly shed their magnets and lock up the starter!). Obviously, my first suspicion is a run down or dying battery. In such a condition the battery may have enough juice to light the lights and cause the starter relay to pull in its contact, but not enough left to turn over the starter motor. Have it load tested after an overnight charge to check condition.
If the battery is good (and assuming that the bike then starts normally), then proceed to check out your charging system. Does the red generator light on the dash have a soft glow? After initial start up and raising the rpm's for the first time over ~1500 rpm, the light should go out. If not, time to read up on Snowbum's airhead charging system treatise.
Other possibilities: Loose or corroded connections between the battery and the starter or the battery and ground. Starting at the battery, check all the connections. The positive cable goes forward under the tank to the starter relay, and then into the top of the engine casing. In addition to the battery and starter connections, pull the plug off the bottom of the relay and inspect the relay contacts and the female contacts in the plug -- a common area of corrosion build-up. A mild warning on the ground cable -- the bottom of the cable is attached to the transmission by a bolt. The bolt has a hole in it -- a vent which must be kept clear (and thus not relaced with just "any" bolt). The bolt is also easy to strip out of the soft aluminum tranny case if too much tighening torque is applied. (and while you are down in that area, inspect the rubber boot on the speedo drive cable -- a well-know point of tranny-destroying water ingress).
Also, if for some reason you remove the engine front cover (for example, chasing down a charging issue) you MUST disconnect the battery ground before hand -- if you do not and you contact the cover to the bike and the electrics inside, the resulting dead short can fry the diode board - $$$.