If you can, monitor the battery voltage when you apply the start button. Many times a battery may show a good voltage until a load is applied at which point the voltage will drop off sharply indicating the battery is in need of replacement. Depending on the severity of the problem with the battery it could run fine but fall on it's face when a significant load is applied (cranking the engine).
Also if you jump it again check the voltage of the battery while the bike is running...should be in the vicinity of 14.5 volts.
I have seen on more than one occasion wring harnesses that have connectors with slight corrosion throughout the harness. This can cause a voltage drop in the harness that will be significant enough to where the start relay cannot be actuated. Find a clip cord and bypass the harness by running the cord directly from battery positive to the positive side of your start relay. Be aware that is doing this you are bypassing any safety switches in the system (sidestand, clutch, nuetral) so be sure the bike is out of gear before trying this. Connect your meter between a good ground and the starter side of your start relay, watch for battery voltage when you try and activate the relay. If battery voltage looks good then it may well be the starter motor.
You can also bypass the relay by using a jumper cable and running it from battery positive directly to the positive of the starter motor itself....again...make sure the bike is in neutral.
While you are at all this check for the tightness of all fasteners you encounter, particularly the ground. A dodgy ground can cause no end of head scratching. Sometimes as well a fastener may appear tight but has corrosion at the connection. It is a good idea to undo the connections for inspection and clean them up with a small brass brush and some contact cleaning type spray.
SOURCE: Starting problem S&S 96 CI engine
sounds like the starter solonoid is not working properly if the batt cable got hot enough to smoke that says the batt, is ok and it is ok to jump with car, the solonoid is making the clicking noise and a real hot batt sometimes will make it work, the repair is simple and cheap if you are talented just get a solonoid repair kit three screws 5 min, and you are RIDEING.
SOURCE: Starting Issue for my 1982 Honda GL1100 Aspencade
glad to hear it was only the battery.
when you buy one (either from a store or online), be sure to trickle charge it completely BEFORE using it on the bike. gotta start with a fully charged battery or it will never perform properly in the future.
online stores will sell you "dry" batteries so you'll have to buy some acid at your local auto parts store. if you get it from a store, it should come "wet". both will need a charge first.
2 years is about right for a lead-acid battery especially the lower end units. if you go with a yuasa brand, expect additional 1 to 2 years.
glad i could help. enjoy that classic!
SOURCE: No start or turn over. Battery registers 13 volts. Stopped for
Its a bad earth between battery and chassis or starter and chassis
Testimonial: "bournetoride: Your suggestion on earth was excellent. Turns out battery could not pass a load test. No prior indication of failure. "
SOURCE: wifes harley 2007 1200L sporster, started ran
Take the spark plugs out of the engine and see if the engine turns over then. If it does but the engine will not turn over with the plugs in it, have the battery checked. Never assume a battery is good because it's not very old.
If the engine will not turn over with the spark plugs out, it sounds like may have serious problems. In this case, I'd consult a professional mechanic.
You can repost if you find out more information for us to work from. Good Luck
SOURCE: 1985 R80 40,000 miles. Battery has difficulty
If battery and starter are as good as you say try checking the condition of the earth leads from battery to frame and any earths from engine/starter motor to frame. A corroded terminal could be the problem. Also check pos wire from battery to starter and any relay in system.
Testimonial: "changed oil as advised. Bike started first time this morning. Very grateful. Many thanks."
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