I bought a 1996 FLHT with 40K miles 6 months ago. I put a new battery 2 months ago and recently after several 6 hour trips on the weekend the bike sits in the garage connected to a battery tender. After a week I go to start and all I get is a clicking sound like low voltage can't pull in the starter coil but there is also a slight "clicking" coming from inside the batwing. During the ride and while idle charging meter above 14VDC. Also digital metered while idle and 14VDC. I then connect battery to a full charger and it takes a short charge and all normal. Took battery out and had tested and doesn't appear to have a bad cell. Any thoughts??

 

You already have a good battery so rule that out.

You can use a voltmeter to read the battery voltage while depressing the starter button...If the battery voltage drops below 8-volts it usually indicates the solenoid is drawing too much current...

 

Starter relay?

 

That too! A faulty starter relay can cause the same nightmare!!

 

Check the stud on top of the starter.....

Fairly common place to find corrosion and sometimes the nuts can be loose.

When you get it repaired....it might be a good time to install the push button on the end of the starter. Great to have a backup push button and is great for troubleshooting.

 

To rule out back connection at handle bar button you can pull the end cover off of starter and try a manual start bipassing handle bar button. If I heard a slight click in bat wing I would be checking circuit breakers in there.

 

Sounds like ur starter relay. I had same issue a while ago.

 

Okay thanks for all of the replies and I'll check them out this weekend as rain is expected all weekend. I don't have a wiring diagram so where is the starter relay?

 

it should be under the front fairing. Take the headlight out and you should see it just to the left side of the bike from center. Have someone hit the starter button and feel the two relays to see which one is clicking.

 

My bet is the starter solenoid. That's what catches the most wear. Especially since some people have a bad habit of not holding it in long enough for the v-twin to start. They get two or three false starts. Ever time the big contact on the solenoid makes it pull 100-150 amps for the starter. Enough of these and it will not make good contact. On mine you can pull solenoid without pulling starter.