It had been having problems not keeping a charge,kept getting "click" after only a short time.Replaced the 5 yr. old battery. Perfect,except after a 3 mile ride,"click" again. Do all elec. tests,not getting charging voltage when running,only 11 v across terminals.Re-charge battery, I even took out stater and did bench tests,it passed,I re-install it and it starts right up. Cool,now I'll just get a reg/rec and be good. Install new reg/rec and button it all back up and " click,click,click" . WTF Help please.

 

There are lots of threads about this problem. Enter 'starter click' in 'Search this Forum' and you will find plenty of suggestions to help you through this.

 

Check the negative connection at the battery,Sometimes it seems to be okay but a half turn makes a difference.

 

Think its possible for the starter and solenoid to pass all the bench tests,then when it re-installed,clicks again ? I removed the starter,I took the solenoid apart and cleaned the contacts and cleaned up all the connections. I installed it all and it started right up! Ran for 5 mins then popped a breaker. The key switch was bad. So, I replaced it,and it clicks all over again. I just wonder with the starter being under load,is it just too tired to turn the engine over ? I did continuity checks on all the connectors,and voltage drop tests as per manual flow chart and it failed for the battery connection. The battery connection post turns just a fuzz when I loosen the nut. Hmmmmmm