First, I apologize if this has already been covered somewhere (I'm a newbie). I picked up an old Sporty to tinker with over the winter and now have a starting issue. When I hit the starter, the solenoid clicks - nothing else. The battery is fresh (took the one out of my shovel - even tried new battery pack). Took the starter off had it bench tested at a shop - its good. I have power to the solenoid, but nothing after. Can it be faulty even if it is clicking (hammering into place)? I always thought if it clicked, it was engaging/working? Am I missing something simple? I cross the soleniod terminals with a bolt and the power goes to the starter and it rolls over.
Thanks for your help.

 

The solenoid may be mechanically actuating (clicking), but the solenoid contacts may be burnt and not passing enough current to the starter.

 

Right. Ok, that makes sense to me and confirms I am on the right trail.
Thanks for your help. I see on line the repair kits are more expensive than just buying another solenoid (seems odd to me). Anyway I'll swap it out and go from there.
Cheers

 

Okay, so I put the new solenoid in and nothing (a little smoke at the positive side of the solenoid). So I pull the negative battery ground off the frame, grind to new metal and reinstall. Now the new solenoid is clicking (like the old one) and the starter is making a low spinning sound (but not cranking over the motor). I would suspect the bendix, but when I cross the soleniod terminals and force more current directly to the starter, it rolls the motor over. What am I missing? I have not taken the primary off yet (hoping to avoid this, but will if necessary), but is there something that is preventing the starter from getting the juice it needs? Any help appreciated. Thanks again!!
Oh, one other thing. Not sure if this is related. During the winter when I would pull the clutch in(move bike around shop), it would make a metalic sound on the primary side (this has now stopped). Is this the clutch basket and could it affect appropriate solenoid accuation/meshing?

 

I'm not familiar with the Ironhead starter circuit, but does the "start" button feed to a starter relay which then feeds to the starter solenoid?

When you say you jumped the solenoid terminals, are you referring to the input terminals or the high current contacts?

What happens if you use a jumper cable to jump the batteries +12 to the solenoid 12v control terminal?

 

If your solenoid is working and the starter contacts are clean, I'd check the starter itself. (Battery power to the starter contact. ).

 

I crossed the high current poles on the solenoid with a bolt and the bike rolled over. My gut is: if when crossed, I am simply by-passing the starter button/key. If it is able to roll over when I do this, the issue is pre-solenoid, as the solenoid, starter and bendix are working fine when I do this. You mentioned starter relay - this and poor wiring/connections pre-solenoid must be responsible. I plan to by-pass the current ignition set up, and insert toggle switch direct to solenoid and see if this works (no time today).
Thanks for your feedback/comments - any more are welcome.
Cheers