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500 Start Up Issues

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philward:
Well got it sorted - and it was a simple fault. As suggested by Ken, starter cable pinched between case and sprocket cover (not were I thought and was careful when installing - near alternator case via grommet) but were alternator and starter lead come out (in the 'u' in the crankcase thats specifically for the cable exit). This is were it exited originally (when I stripped the bike) but as the alternator lead and starter cable are a real tight fit through this point, I've re-routed it under the engine bolt (above sprocket cover chain guard/plastic rear chain guard) and up the rear of the frame tube. Not sure that this is the correct route but its the most smooth/non shaiffing route.
I still read a ground on the lead but its from the ground on the other side of the motor windings (which is shunted to the other side of the motor windings when the solenoid applies a live) - as per the test on my 750 curcuit - as opposed to the 'shorting' ground which applied a direct ground to the live when switched.
M&P are replacing Motobatt too!

K2-K6:
Good news you got to the bottom of it,  and good job you didn't put the other battery on there! Lucky with the motobatt too  :)

McCabe-Thiele (Ted):

--- Quote from: philward on March 16, 2021, 05:30:14 PM ---I am grasping at straws Ted - I have been on Youtube and the parallel (or tandem) technique was suggested a few times - its an optimiser but have an old school charger as well (about 30 years old I guess) - which one do you suggest? May be a duff new battery and sparks from from when jump leads attached may be caused by inadequate contact between jump lead crocadile clip and bike leads (for starter motor current draw) - hence it went to zero as it was duff, not because of a short via solenoid (see previous post on a ground also showing on my fully working 750 starter lead.

--- End quote ---

I see you found the cause of the problem  - still annoying when you find its something realtively basic but job well done.Ted

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