I dealt with that dreaded click for 6 months before finally installing the extra relay under the seat. Never had a minutes trouble since then. You can buy the relay at autozone. Several people on here have posted detailed instructions on hooking it up. It's simple. Do a search on this site under the name "Galtjunk". I remember him posting detailed instructions on the relay, along with several other people, Dr. Hess included. The relay from autozone is only about 6 dollars. Takes about 30 minutes to hook it up. Before I wired the relay, I had installed a new solenoid, battery, triple checked all the connections, installed a push button solenoid, and was getting ready to buy a new starter when I finally decided to try adding the relay under the seat. That's what fixed it.

 

Here`s a link to the post by Dr. Hess:

Post #9

https://www.hdforums.com/forum/evo-c...-question.html

 

Thanks Dan that is what I was looking for before I started this thread.

 

DR Hess I could be wrong but I could have swore I was watching a Youtube vid the other day on testing batteries and he had said anything about 9.something volts when the starter was pushed was a good battery, I tried this on mine with a volt meter on my battery and sure enough it blipped down just above 9.somthing volts and my bike starts np.
Texas you may have to give a good overnite charge with a 4amp charger and that will give the starter a good hit. Although a 2amp overnite will give a good longeveity charge. By the way when I did Dr Hess's dreaded click relay fix I copied a pic of my setup in my album. I kept the old relay and just parellel wired in the second relay. I also rewired so I could shut my lites off for starting. Also all the suggestions the guys made have to be done too. A good starting bike is a must.

 

If you're just getting a click and not spinning the starter, then 10V is going to be low, as the only load on that should be solenoid, which I think is about 10 amps, if I recall. The battery should not drop to 10V with a 10 amp draw, I don't think. Anyway, I think it's borderline and almost time to replace it anyway.

I have more comments further down in the thread linked to above. We really need to book mark that one and the How To Diagnose Your Electrical System one. Really needs a sticky.

 

Thanks for the picture that will help me a lot.
Where did you get the wiring directions to change the wiring on your ignition switch?

 

LOL from the Doc of course

 

I previously copied How To Diagnose Your Electrical System to a word document. It is great information. That is part of the reason I was kicking myself in the *** for not doing it for your adding a relay guide.

I have a new battery trickle charging right now and will install it in the morning. I will also look at adding a relay while I am in there.

 

Was it in a thread and if so which one or do you still have the procedure?

 

Tex, try this first. Remove seat, put bike in neutral, and press start button. When relay under seat clicks tap it with a hammer (while holding start button. If she cranks, it's the relay.