I have a new to me '91 TG. I've had it a few weeks, runs great, but when I start it one of 2 things generally happens. It will either do nothing when I hit the starter, then I'll release the botton and press it a second time and it will crank. Or, it will crank for a second, hesitate, then continue to crank until it starts. Any thoughts?

 

Bike shuts down on compression stroke which makes it hard to start if you have a weak battery

 

Check out the "adding second relay for fixing dreaded click" thread. There are some good pointers for checking over the system other than just modding the wiring.

 

Here's the thread....https://www.hdforums.com/forum/evo-c...ck-sticky.html

 

First ., clean out the handle bar start switch . While your at it , clean out all the bar switches by disconnecting the battery then shoot some WD40 into each switch while manually cycling each switch as you shoot the cleaner into the switch .
Let switches drain and dry or use compressed air to blow dry.
If this dosent solve the problem , go to next step which is elec. troubleshooting of the relays and starter system.

 

First take the battery and get it load tested. If it is good then clean switches. If problem persists then look at adding a second relay.