Ok so this is how it goes.
I have a 2007 Road Glide. I took off the outer and inner primary covers to have them powder coated. Today I put everything back together and hit the starter button and the relay just goes click.
I made sure I had Batt voltage at the post on the starter. Pull the small wire off the solenoid and had battery voltage when starter button is pushed. Acting like a bad starter. Pull the starter out of the bike and bench test it with a pair of jumper cables and the starter works fine. Reinstall the starter same problem no start. Checked ground cables for corrosion, everything looked good. I even ran a external ground wire from the negative on the battery down to the starter thinking a bad starter ground. Still the relay just goes click.
Starter bolts are torque to the correct torque per service manual. I have double checked and triple checked everything.
Anyone got any ideas?

 

Bump, anyone?

 

put your bike in neutral & roll it on the floor. Is the primary chain free or binding? Are all grounds hooked up? Is your battery voltage over 12 volts?

 

Yes the bike rolls across the floor and the primary chain is free and not binding. Yes all the grounds are hooked up and cleaned. Even added a extra one straight to the starter housing from the battery. Battery is fully charged, as a matter of fact the battery charger was hooked to the battery during all this making sure I had correct battery voltage.

Any other Ideas?

 

Sounds like something is jammed preventing the starter from engaging, if the relay is clicking, and the battery has enough voltage as you say.

 

Just a shot in the dark here but monitor your Batt Voltage when try to start and see what happens ...

 

is there a relay between the starter and the start button???maybe on the fuse panel...

 

If it was working properly before the upgrade, I would start with removing the newly installed parts. It may be a pinched wire or the addition of the powder coating binding something up.

 

I found out what was my problem. My powder coat guy powder coated the mating surface for the starter. Making the starter ground bad. After about a hour with some emory cloth and a razor blade I put the starter back in and hit the switch and the Roadshark came back to life. Thanks everyone for you help.