Recently had my starter not disengage. I took a look a the plunger on the solenoid, and the plunger contacts had welded to the contacts bolted to the sides of the solenoid. After I separated them and pulled the plunger out, I took a little sandpaper and sanded down the contacts a little to make them more smooth.

I went through and checked the wiring system to see what could have caused this. The relay checked good on the ohm meter on both open and closed. I also took an ohm meter to the starter switch on the handlebar and it checked out at 7 ohms. I hooked everything but the positive line going to the starter, and hit the button a few times. Even though it was just engaging the relay, my lights would dim like it was really turning the engine over.

Anyway, I'm going to pickup a new relay and solenoid spring today and change them out. I was wondering if anyone could think of any place else I should check, and why the starting system was acting like it had a load on it when I was just engaging the relay?

 

You might want to have the battery load checked to see if it's still good. Make sure all ground connections are tight too.