I have a similar starting problem with my 2001 Mastiff. I would hit the starter button and hear the ech relay but the bike wouldn't start. This would happen once in a while so I figured it was dirty selonid contacts. Pulled the starter ,cleaned the contacts and bench tested. Worked fine. Installed starter in the bike, hit the starter button and only hear a click from the ECH and now won't start at all. Checked the wire to the selonid when pushing the start button and voltage is there but only about 11.5 Volts., Maybe a resistance problem? I was thinking of bypassing and adding a separate starter switch and a slam button. If I jump the starter with a wire, it works fine. Have not tried jumping from a car. Any suggestions would be greatly appreciated.
What is you battery voltage? If you are less that 12.75 volts it's too low, did you check all your connections and cables? I had some issues like this and bypassed my EHC and it did work but eventually other things went out on my EHC so I had to replace it with DOC's - ESC, and also my start switch pcb board went out so I replaced it also, hopefully it's just a bad cable or connection, check them first and your battery voltage, then go from there.
Battery voltage is 13.2. This is an intermittent problem and after screwing around with it for a while and repeatedly hitting the starter button, it engaged and the starter functioned. I can hear the relay in the ehc operating and believe it is the contacts. This problem left me stranded once and I have since purchased a slam button and carry a short jumper cable I can connect to the selonid and touch to the battery terminal. I will have to research further and not sure if it is actually in the ehc or other wiring but suspecting the relay is the problem. Can these units be repaired and components be replaced? For now if anyone else is having this problem, I crimped a 1/4 inch female spade connector to a 6 " piece 12 GA wire and use this as a jumper which I now carry with me always. Thanks so much for your response!
If you can jump it off the solenoid its not the contacts that is the problem. Check your voltage to the solenoid contact when you hit start, I would suspect its not getting 12+ Volts thats why the jumper wire works. Check the relay like Dave said above.
If it's an intermittent problem I would check the run/start circuit board to see if it's bad, to check it remove the one from the left side and plug it into the right side, the button locations will be different but at least you will know if your pcb is bad or not, I also had it happening intermittently at first.
