bad to worse

[chris_blake]

managed to remove clutch piston and bearing both are fine no pitting bearings move freely i can now see what you mean about the rod i will have to get some sort of screw or bolt in but i think the swingarm will have to be removed anyway i thought i would try a test ride just to check on starting the bike i got a loud grinding noise from i think the starter motor as soon as i turned on the ignition without pressing the starter button this then stopped i pushed the starter button and bike started when i twisted the throttle it made the noise again as if the starter motor was trying to turn also when this occured the headlight went off  this happened 4 or 5 times and then stopped  once the engine was warm i could not get it to repeat it could it be a faulty starter relay or is it linked to the clutch problem any advice as always much appreciated i am beginning to think this bike has had a pretty hard life with its previous owner even though it is low mileage only 22'000 miles

[Bob_Roller]

I had a similar occurance that you described, it happened after I washed the bike, I blew out the starter switch with compressed air, and it never came back.

If your headlight goes out when this happens, the lighting relay is de-energized when the starter is activated by the start switch and starter relay.

[chris_blake]

thanks bob when you say the starter switch do you mean the starter button

[Bob_Roller]

Yes I meant start button, I have an aviation maintenance background, and tend to call things more in a technical sense than it really needs to be outside of work.

[tagordon]

FWIW
I know a R65 rider that had the starter engage while at traffic speed. Destoryed the flywheel & starter completely.
He said it happened briefly a couple times before the destructive occurrance. But he did not know what the noise was.  

[chris_blake]

followed your advice bob and it started fine this seems to be temperature related  i will keep you infomed as we are due some pretty cold weather due this week thanks again'