Xtreme, I had the same problem with my 2001. Take your seat off and the black box behind your battery, the CDI. Tap on it and she'll pop right off. I cleaned the hell out every connection to the Box. The only thing that worked was smackin it with the screwdriver. Good luck.

 

Same problem here.......RED positive terminal connection came loose.........goes "klank" when you try to start.

 

I had the positive terminal come loose multiple times. My last "no start" problem was when I installed the engine (when the tranny imploded) and did'nt attach a wire correct and smoked my relay. Mine had the clicking as you speak of coming from the relay and the fuse was perfect. I could still push start and ride fine. I changed the relay and all was fine....about $30.

 

Mine is dead at the shop right now with those exact conditions. The starter spun as if it wasnt engaging, I pull started it and on the way back to camp , it died, now nadda,it just makes a large clicking sound at the relay, but I checked my fuses, my shop was thinking starter or strarter clutch ?? You guys think the relay ???

 

If it died while you were riding, it might be your charging system. Have you tried charging your battery?

 

No, because it was spinning making the dreaded whirling noise and wouldnt engage the strter or should I say the strter wasnt engaging, checked bike @ camp, piston would turn over , at least it wasnt the crank, this is my second one, the first died a horrible grinding noise.

 

OK guys here goes: The gentleman who did my piston and cam install thinks the connecting rod may have let go!![img]i/expressions/face-icon-small-sad.gif[/img] I hope he's wrong!!! Thanks for all the info and insight!!!!!!! I will let you guys know EXACTLY what's wrong when I find out!!!!! Xtreme

 

Anybody else have the same thing happen?[img]i/expressions/face-icon-small-disgusted.gif[/img]

 

cross yer fingers... heck, cross everything! good luck
[img]i/expressions/face-icon-small-tongue.gif[/img]

 

Rigo- Well??? do the motor blow??? That is a pisser. Did the motor guy bore and hone the new piston or just slap it in???