Motorcycle Repair: 1982 Virago XV750 suddenly doesnt start, yamaha virago xv750, starter relay

Question
Hi Wayne,

I have a 1982 Yamaha Virago XV750.

I was trying to replace a TCI unit on my bike last weekend, and here's what happened:

I disconnected the old TCI and connected the new TCI (didn't mount it yet);  I tried starting up the bike, and it worked perfectly.  I kept going back and forth, connecting the old TCI and starting it up, and then the new TCI and starting it up, to compare the idling and revving of each.

Anyway, I decided I was happy with the results, so I mounted the new TCI properly and tried to start the bike.  The bike then went a little haywire!  I pressed the start button, but the bike didn't turn over - the tach jumped to 3000 (even though the bike wasn't running) and every time I pressed the 'start' button, the starter relay would just make a loud single 'click' and the right blinker would flash.  Weird, right?  Anyway, I put the original TCI back in, and now I still get the loud single 'click' when I try to start the bike;  the engine doesn't turn over at all.  I did verify that it's the starter relay clicking because I felt it with my hand.

I also did the following, just for giggles:

- I checked the battery, and even though the battery is a bit old, a voltmeter reads the voltage as 12.05V.

- I took a screwdriver and laid it across the contacts on the starter relay, and it got a huge spark, so there seems to be power going to the relay.

What do you think?  Is there anything I missed?  Is there something obviously wrong that my novice tech skills missed?

Thanks a lot for your time!

-mike

Answer
Mike,

Here is a Virago starting system diagram:
http://wsamel.fortunecity.com/virago-starter-wiring.jpg

-the battery sounds a bit low for being fully charged.
Try charging the battery, then briefly try
connecting the large solenoid terminals again.
-The starter should crank, if not, try connecting
the battery directly to the starter itself.
If it doesn't crank, the starter needs to
be checked out. This is assuming the battery is okay.
-The starting system uses some smaller relays
but since it was clicking it sounds like
power is getting to the solenoid from the
small relays.
-NOTE: When I say solenoid I mean the
relay with the big starter cables on it,
not the smaller relays which may click as well.