isnt there something you can turn to help the starter crank the motor over?
I had the same prob when i put my Baja back together, lots of clickin when u hit the starter and soemtimes it would fire but most times it would not, i swapped the voltage regulator, starter cylinoids, the starter itself, battery, and cleaned the grounds hardcore! yet still the problem, so finally the 1 time it did crank over i put it in gear and rode it, problem solved ever since. I guess the Rotax setup has so many parts from starter to firing that they need to be in sync, only weird thing is your DS was runnin when it quit on ya

 

Bench test your starter and check your starter relay. Put some jumps straight to the starter connections with it installed on the bike. Check the voltage at the relay as well. If those are good, I think you need to replace the CDI, Rectifier, and Battery. Then make absolutley sure that ALL your grounds are good. Here is what happens... ground begins to corrode making intermitent connection. This will burn up your CDI... ask ERBE, his bad ground burned up a very nice Vortex box. I would guess the same process is damaging your Rect. The bad rect. will give you a false reading on your battery. Don't ask me how it happens... I'm no engineer but I have had a battery read fully charged and then not be able to start my bike. Get a PC545, it is the best battery out there for most applications.

 

Don't know if this will help, but I have gone threw 3 multi function switchs - the starter button is in there. When mine would fail it would turn over sometimes and sometime just click. I could allways jump it by touching the 2 posts on the starter solenoid.

There is testing procedures for this in the manual. Don't know if you have a manual and a multi-meter, but I can photo copy the pages and send them to you if you need.

 

No the motor did not crank as it should....made slight clicking noise at first then quit, wouldn't make any noise after 1st attempt

 

<div class="FTQUOTE"><begin quote>Originally posted by: FatHolly

Bench test your starter and check your starter relay. Put some jumps straight to the starter connections with it installed on the bike. Check the voltage at the relay as well. If those are good, I think you need to replace the CDI, Rectifier, and Battery. Then make absolutley sure that ALL your grounds are good. Here is what happens... ground begins to corrode making intermitent connection. This will burn up your CDI... ask ERBE, his bad ground burned up a very nice Vortex box. I would guess the same process is damaging your Rect. The bad rect. will give you a false reading on your battery. Don't ask me how it happens... I'm no engineer but I have had a battery read fully charged and then not be able to start my bike. Get a PC545, it is the best battery out there for most applications.</end quote></div>

With a battery charger? I am unsure of what you're saying with this.

 

<div class="FTQUOTE"><begin quote>Originally posted by: FatHolly

Bench test your starter and check your starter relay. Put some jumps straight to the starter connections with it installed on the bike. Check the voltage at the relay as well. If those are good, I think you need to replace the CDI, Rectifier, and Battery. Then make absolutley sure that ALL your grounds are good. Here is what happens... ground begins to corrode making intermitent connection. This will burn up your CDI... ask ERBE, his bad ground burned up a very nice Vortex box. I would guess the same process is damaging your Rect. The bad rect. will give you a false reading on your battery. Don't ask me how it happens... I'm no engineer but I have had a battery read fully charged and then not be able to start my bike. Get a PC545, it is the best battery out there for most applications.</end quote></div>


Well I replaced the Big Gun with the stock unit and the bike fired once...then nothing. I Also replaced the rectifier and had a brand new battery when this occurred. I hope I didn't fry all fo that, but I checked all of the grounds at least 5 times each now.

 

<div class="FTQUOTE"><begin quote>Originally posted by: MRDS650

Don't know if this will help, but I have gone threw 3 multi function switchs - the starter button is in there. When mine would fail it would turn over sometimes and sometime just click. I could allways jump it by touching the 2 posts on the starter solenoid.



There is testing procedures for this in the manual. Don't know if you have a manual and a multi-meter, but I can photo copy the pages and send them to you if you need.</end quote></div>


My buddy and I had this thought a while back, but the bike would crank but not fire or pop start when I started having the issues. Now it won't even crank. I will try to jump it using the 2 starter posts.

 

well if u need another voltage regulator, starter cylinoids, or possibly a starter let me know

 

<div class="FTQUOTE"><begin quote>Originally posted by: NickDS650

well if u need another voltage regulator, starter cylinoids, or possibly a starter let me know</end quote></div>

Really? Because I was on Ebay today looking for a starter relay, starter, solenoids, coils, etc. I have been looking for cheap(ish) stock parts to trial and error with. What all do you have? How much do you want for what you have? Email me if you like wevs24@sbcglobal.net . Thanks.