2005 Mastiff wont start

Energy One
Haven't ridden the bike in 2 years- Went to start it nothing...Even tho the bike was always on a tender the whole time it was time for a new battery.
Purchased new battery a Yuosa with 320CCA. Nothing
So what i have done to this point-
Meter on the battery 12.7V
Have power to the solenoid (light checked)- When i hit run on the upper control button i see the ignition module activate (redlight), when i push start the headlight dims and i can hear a click. When i push that start button the connector wire from the solenoid to the starter, lights up the test light so its getting power there too.
When i put the meter on the green wire and push the run/start button i get 11.7 Volts but absolutely no crank over. I don't wanna just start replacing shit until one thing fixes the problem. At this point i am thinking a new starter is needed.
From your guys' much more vast knowledge than mine is there anything else that i should check to further isolate the problem?

Thanks in advance Bob
 

chubs

Guru
i had a similar situation one time, good power to the green solenoid connecter but no crank. pulled the end cover off the solenoid and found one of the little wires between the green wire connection and where it entered the solenoid. soldered the break back together and haven't had any problems yet. (just a thought) P.S. While you have the cover off, check the starter contacts and maybe clean them up a bit. Disconnect the battery first to be on the safe side!
 
Ok i pulled the cover off the solenoid used emery cloth on the copper ring on the plunger, cleaned up the contacts inside the solenoid, looked at the two "straps" both appear to be intact (connected), put it all back together and still wont crank.

Looking at the control board under the seat there is only one red light illuminated and one red light on the ignition module after i hit the run button.

When i hit the start button i hear a click of what i imagine is the solenoid and a green light becomes present on the computer board under the seat. I don't believe any other lights happen on the ignition module. Does that seem like enough lights are lit up on the board at that stage in the process? In other words should there be more lights and the board might be dead

Sequencially is it-
*Key on
Run button- sends ignition module a signal
run button- EHC sends signal to green wire and closes solenoid
Solenoid makes contacts and sends power to the starter and the starter and should crank the engine over.
At what point does the coil come into the equation, Cam sensor?
 
Just ran a "jumper wire" from the hot wire on top of the solenoid to the green spade connector (where the green wire is) in hopes of bypassing the solenoid and forcing the starter to spin..It only clicked on the solenoid.
At this point i am leaning heavily on a starter being the issue for the fact i have measured voltage to it at the green wire and got 11.8 Volts, so i know the upper handlebar switch and EHC is allowing/sending signal. I ran the jumper from a known 12v source directly to the spade and it would NOT turn it over.



My thought is if the ECH was bad, when i bypassed any signal from the ECH the starter (if good), just direct voltage it would have turned it over and it didnt.

Thoughts? Does it sound like my test of the starter/Solenoid was done correctly?
 
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