I was getting a clicking sound from my 99 wolvy when i would try and start it. I tracked this noise to the starter assy just under the left rear fender. After close examination the blue wire was barely attached to the switch so I removed it so that I could solder this connection. Well in removing the starter switch assy the blue wire broke off completely so of course I ordered a new one. It came in and I I installed it, thinking I solved the problem. Well I get the same loud clicking noise with this new part, so it has to be something else??? Also I do have a battery charger hooked up and this does not help with turning it over. Please help diagnose this problem, I need help!!

 

Clean battery connections and check connection at starter, is the battery any good?

 

i had a problem like that on my warrior and it was a lose connection on my battery..maybe your battery is to weak or in worse case the bike is not seized up is it

 

I have had the EXACT same problem and have traced it down to the same place. It hasn't been a real issue yet, it only happens once or twice when I turn the key, then all the sudden it starts, Don't know why. (???) Just hope it doesn't leave me stranded one day.

 

I would also check your starter. I had the same thing and everything checked out but it wouldn't turn over. I tapped on the starter with a hammer and boom she started right up. I pulled the starter out and had it rebuilt.

 

Have the battery load tested. And while the battery is out, clean the terminals on both the battery and the wires.
What causes the clicking of the solinoid? Its just an elctromagnet inside, and when you first press the start button, the full battery voltage makes it to the solinoid, closing the contacts. This is the first click. Now the starter s connected to the battery, and because the resistance of the starter is very low, it will pull alot of amps. When the starter pulls the amps, the battery is too weak, or the connections too dirty, and the voltage drops. Once the voltage drops, the solinoid kicks off. Sometimes it happens so fast, it sounds like its buzzing. Anyway, if you put a voltmeter accross the battery while cranking it, you can see this happening.
Thats basicly what a load test does to a battery, it applies a low resitance load, and watches what happens to the voltage. If the battery is weak, the voltage will drop when the load is applied.

 

If you search my name here I have answered several threads regarding testing your complete system from A to Z and eliminating all guesswork. Let me know if you can not find my threads and I'll walk you through it. Just for kicks tho try jumping a heavy wire or a pair of pliers or screwdriver across the heavy terminals on the solonoid. (thing that is clicking). The starter should spin over if the battery, starter and wiring and connections are all good. If it does you probably pinpointed a bad solonoid. Look up my threads tho for detailed testing and several quick testing tricks to do using a multimeter and/or test light.

 

ya might want to listen to renegade888 this guy knows his stuff.[img]i/expressions/face-icon-small-cool.gif[/img]