Thanks for the good advice. Cheers

 

I'm having real bad luck lately, I just finished putting new anti freeze and running it for about 1/2 hour to get all the air out. When I was happy to see that everything is working,fan,circulation and no overheating I turned it off and tried to restart it. Now it won't start,solenoid just clicks. It started about 20 times yesterday with no problems.
OldPolarisTech can I message you directly?

 

Just trace it down. Start with the battery and connections,load test it if there is any doubt.When the solenoid clicks check to see if power is transferred to the starter cable. If not,then the solenoid is bad. If power is going to the starter,loosen the 10mm nut and move the cable around to try to get a better contact,then tighten the nut.If that doesn't help,then tap on the starter as you try to crank it. It it works then the brushes could be worn and dirty,armature where the brushes ride may be dirty. If it's a starter or even a worn bendix under the recoil housing locking the engine up,these can be found cheap on ebay.Not a bad idea when you get it running to check voltage at the battery to see if the regulator is keeping the battery fully charged at around 14volts or so.

 

I did some reading (lots) and came across an article on how to check your charging system and they say to unplug the yellow and yellow/red wire behind the front grill to do test. As soon as I read that I remembered unplugging this wires when I took the grill and rad off. Plugged everything back in charge the battery and all is good. I want to thank you for all your help. If only I knew it was just an air lock none of this would have happened and would have fixed it quick.

 

Yes plugging the regulator wires back in helps.. Regulators had enough problems of their own from vibration and wires would become disconnected and drain batteries.

 

Another problem, while cleaning up inside headlamp assembly because a mouse made a nest a wire broke off a ceramic looking resistor I believe for the heated handlebar grips. Is there anything to use that's better than that, solid stiff wire coming out both ends.

 

These resistors get hot. That's why they use solid wire instead of stranded wire.

 

Ah!!!�� I found some at a local electronic store for $2.99 per 2