Just got home after being stranded for about an hour. 2002 fxdx. Picked it up last weekend. Took it out for a ride, got it back to the garage, tried to start it later and click click click. Would not start or turn over. I messed around the area In the pictures I included and it finally turned over. Today it happened again. Went to get some air in the tires, turned it off got air. Went to start and click click click. Again I wiggled around in the area in the pictures and it finally turned over. Very frustrating as I don't know exactly what it is. Thanks.

 

These problems can be maddening. First pic is the starter relay. They go bad and are cheap to replace. Replace it and buy a spare while you are at it.

Second pic is the diagnostic port to read codes/reprogram the ignition. Pull the end cap off and clean the connections inside with electrical contact cleaner and replace the plug. Check the wiring to make sure that there are no tears in the insulation that could contact a ground. Probably not your problem, but check it anyway.

Next, check the battery to make sure it is at min 12.7V. Flip the run switch next to the throttle to the "off" position and crank it over a few times. See what the battery reads then. If the voltage reading drops a below 12V after a little cranking, it is likely the battery is weak and should be replaced. Recommend a Yuasa battery with 310 or more cold cranking amps. Don't forget to flip the run switch back to "run" before you try to start the engine or it won't.

Take the negative battery cable loose from the stud connecting it to the frame under the seat. Use a wire brush to scrub the terminal and the stud until the are shiny. Replace the battery cable on the stud and tighten firmly.

Remove the other negative cable that runs between the frame and one of the starter bolts. Access is from the exhaust pipe side. Use the wire brush to scrub both terminal ends of the cable and the area around frame stud, removing paint around the stud. Replace the cable, nut, and starter bolt and tighten firmly.

Check that the cables leading to the starter are seated and tight. Do not overtighten the nuts on the starter or you will bend the brushes inside. Just make sure that they are snug and that the trigger cable from the starter relay is plugged securely into the adjoining plug on the starter solenoid. Again, access is from the exhaust pipe side.

These steps should solve your issue. If not, add a battery cable between the frame stud under the seat and the other bolt on your starter.

If that doesn't fix it, probably bad starter solenoid. Don't jump to that step until all other steps are completed as it is the most expensive to fix and the other steps need to be done anyway to avoid problems in the future. Don't ask me how I know.


Good luck.

 

This happened to me with a used bike also. Ran great on the road test then left me dead in the water after coming out of the DMV office.

Found green in the fuse box terminals pretty quick. Borrowed a can of WD40 and cleaned it up better when I got home.

And ditto to what Dyna says!

 

Before changing things on a whim, Get a relay fr later, and ride it. When it happens again, and you hear the dreaded click, try tapping the relay while holding the start button down.
And make sure your in neutral when you do. If it energizes the starter then you KNOW that's it. THEN replace it.

 

Guess I assumed that the OP wanted to AVOID getting stranded by the roadside.

 

That's OK DynaWG1, your advice is spot on.

 

Still guessing. And that's why I said get the relay. So when it happens again and if that was it after confirming it was actually it. He could change it on the road. It's not that difficult to access.
But I guess changing an $8 part that may not need changing is how you fix things.
Hey how about this, starter could be bad, battery may be weak or failing. Lets change those too.

 

Do you wait until you run out of gas to get more?

 

Good one.....I'll have to try that.... lol....

 

Thanks dyna. Will try all of those today. 👍