05 chopper wont start

[Bigdogchopper]

Need some help on this one, hope I can get some input.
05 chopper owned for 2 years now really love my bd have had no elec issues prior other than batteries.
Anyway, Wont turn over just clicks and headlight goes out when pushing start button, comes back on when released.
Clicking noise sounds like and feels like it is coming out of top of front of cylinder head of all places. Battery is brand new and have rechecked twice.
Checked electrical, power to starter and coil with key on, all good, yet will not turn over, just clicks.
Tried push starting..got nothing. Hot wired to starter nothing. Like I said has power to coil. There are 3 leads on coil all show hot with ignition on. I am at a loss short of replacing ecm and wiring harness and then really not sure if that could be problem. Is there some starter relay I am not aware of. One more thing there are wire leads running from coil to under rocker covers that would really like to know what they do. Have not seen that before.
Any diagnostic help any one has would be much appreciated.
Thanks very much.

 

[Sven]

1. Remove spark plugs.
2. Ground spark plugs back into the plug leads, but keep away from the holes or gas will mist out, find that spark and up goes the house. So keep the spark away from the hole.
3. Did the bike turn over easier with the plugs out?
4. Did you see spark?

A. Smell the fuel in the tank.
B. Does the gas smell stale and the breath you took is now in your throat?
C. How old is the gas in the tank?
D. If stored, did you drain gas out of the tank or use a stabilizer?

I. Say compression is a given.
II. Say we let the bike sit, shows a poor ground somewhere and rusts?
III. Can we say our negative lead to the frame has good contact?
IV. Current draw on a new battery? Can we use that same battery and start another bike? If not... Bad Battery. Have it pro-rated, or buy quality. Is this some off the wall replacement battery?

 

[spadesluck]

First off welcome to the forum. You really should go to the home page and introduce yourself.

If your sure the battery is good it sounds like the starter itself. Mine did this because it was all gummed up inside, common problem from primary oil getting inside. Just try tapping on the starter while hitting the start button see if it tries to engage, if it does the starter is the problem. I would not go straight to the EHC being bad at this point.

 

[KaptinAmerika]

Remove your starter solenoid cover.
Take a screwdriver by the blade end and push the solenoid plunger in with the plastic handle.
Starter should spin over with no issues.
If it doesn't then the starter needs to be rebuilt.
If it does then you likely have a pcb board starter button issue or an issue somewhere in the wiring harness
The above is based on your earlier statement that the battery and main positive and negative cables are good with good connections at both ends.

 

[Nukeranger]

The EHC turns the Headlight off during starting. Be sure you are in neutral when you do as Curtis says above. Don't be scared but be ready to jump because it may surprise you if you aren't familiar with manually energizing a starter.

 

[RRRUFF]

Remove your starter solenoid cover.
Take a screwdriver by the blade end and push the solenoid plunger in with the plastic handle.
Starter should spin over with no issues.
If it doesn't then the starter needs to be rebuilt.
If it does then you likely have a pcb board starter button issue or an issue somewhere in the wiring harness
The above is based on your earlier statement that the battery and main positive and negative cables are good with good connections at both ends.

:2thumbs: Also check the negative battery cable at the ground bolt on the starter.

 

[ringo]

wires at rocker covers are to the compression releases, which as the name implies, temporarily releases compression allowing the engine to spin over easily at start up.

 

[bigdogtech01]

Remove your starter solenoid cover.
Take a screwdriver by the blade end and push the solenoid plunger in with the plastic handle.
Starter should spin over with no issues.
If it doesn't then the starter needs to be rebuilt.
If it does then you likely have a pcb board starter button issue or an issue somewhere in the wiring harness
The above is based on your earlier statement that the battery and main positive and negative cables are good with good connections at both ends.

Agree!! Also, the clicking noise your hearing is the compression releases (both front and rear cyl should be making noise) this is normal. This tells me the signal from the PCB (starter button) is getting to the EHC. The starter solenoid inside the EHC may be faulty. Have you noticed any fault LED lights on on the EHC?