Suzuki GS400 Starter relay

MY Suzuki GS400 has developed a problem with the starter relay. When I
start the bike the terminals on the relay begin to burn! Why is this?
Relay clicks but does not turn starter motor! At a loss, please help!

Gray

 

Very likely the terminals are not making good contact due to corrosion or just
being loose. First, disconnect your battery negative lead. Then remove and clean
the relay terminals and the relay. Connect the battery back up and try it again.

 

<Nods in agreement>

 

Are the large cables the ones that are burning or the small wires?

The big cables burning indicate a possible shorted out starter or a
jammed starter clutch. Remove the alternator cover and take the small
reduction gear off the shaft and see if the starter then turns freely
when you push the button. The larger idler gear will only turn freely
in the counterclockwise direction, it is supposed to engage the
crankshaft in the normal clockwise direction. Broken bolts that are
supposed to secure the starter clutch to the back of the alternator can
jam the starter clutch. Remove the starter and see if you can turn it
freely by hand.

The smaller wires burning might indicate a shorted starter solenoid
coil