Got a new air filter today, oiled it and installed, tried to fire her up and it wouldnt turn over...????? starter would engage and make a humming noise but wouldnt turn it. battery is 2 mos old was reading 12.8 with the tender, 12.5 after i unplugged it. still should be plenty of juice to turn her over. so much for the start module
Pull the cover off of the starter solenoid and inspect the upper contact (battery connection) and the lower contact (starter motor connection) as well as the copper contact washer on the solenoid plunger for pitting and burn marks. Verify that the upper and lower contacts are parallel to the contact washer. It only takes about 80 inch pounds of torque to cause the contact to rotate. When either of theses contacts rotate, it will result in a reduced contact surface between the washer and the contact which means you will be trying to pump over 200 amps through a reduced contact surface which will not be enough to allow the starter to turn over the engine.
If everything looks good, push the solenoid plunger in with your finger till it makes contact and see if this will allow the engine to turn over.
If your not getting sufficient current to the starter, it will hum because it has stalled. This will ultimately cause arcing between the brushes and comutator of the starter motor and the symptoms will get progressively worse.
Take some jumper cables and with the solenoid plunger removed, jumper from the upper post to the lower post bypassing the solenoid altogether to see if the starter motor still spins.
If you have a good digital camera, take some close pictures of the contacts and plunger and I'll have a look at them for you.
You should stop throwing parts at the problem and do some troubleshooting...I'll help you out, but the bike is in front of you not me.
Take a deep breath, do a shot or two of your favorite beverage, smoke a doob, or whatever, and when all is calm, I'll walk you through some troubleshooting!
Have you checked out Gas Mans post above? There are some good pictures of what I'm talking about. check em out.
I never received a PM from you either....:2thumbs: