Motorcycle Repair: Electrical problem.., suzuki intruder, intruder 1400

Question
Man, I need help! I'm pretty well lost. I have a 1993 Suzuki Intruder 1400. Two weeks ago it wouldn't start - acted like a low battery (battery is a Deka bought new this April). The "hot" post actually had melted a little. I jumped the bike off of my Wing - it started and ran fine. Rode it for an hour, turned it off and let it sit for about an hour and a half. Wouldn't start again -  same "Click click" this time a guy gave me a push and she started - ran fine. Took the battery in and had it tested. The guy said it's OK so I put it on the tender and started checking things electrical- used a Clymers Manual for that bike... Found the Starter relay was fried.. Got a new one but still even with a full charge on the battery the engine just grunts like the battery is low. Checked the decompress timers and solenoids - they checked/work fine..even pulled the plugs and tried crankin - still acted like a low battery. Pulled the starter and took it apart. The armature looked worn (metal fins looked way rounded off) so I took it to be checked. The guy said it tested fine.. One thing I've noticed is that the positive battery cable near the battery gets real hot when I try starting.  Now I'm at a standstill. I don't know where to go now - this bike only has 16,000 mi. and has run very well until this situation.. I'm in my mid-50's and don't "flog" the bike at all -it's pretty well pampered... I change oil regularly and it's never used any between changes. Any tips on where to go next would be appreciated! Thanks in advance...  

Answer
Hi Tom,

I suspect the starter motor has too much resistance. I would need to see and inspect it to be certain.

Test it with a known good starter (easier said than obtained).

Test existing starter motor with a 12VDC battery. Connect a cable to the starter motor, ground the starter motor case, and briefly touch the cable end to the Positive terminal. Note what the motor does.

If you send me a email, I will return test and repair files.

mshively1@woh.rr.com


Respectfully,
Mark Shively