The symptoms started with pushing the start button and not even a CLICK. I could hit the start button on the handlebars it would work. So I replaced the starter button on the handlebars. It was fixed for a couple months. sat over the winter. Started riding again no problem. One day I would push the start button and again nothing. no click the lights didn't dim. I pushed started to get home. I checked the battery and load tested. It is a good Battery.
Replaced the starter relay first the lights would dim but no click and the start solenoid didn't engage. the relay smoked a little. I gave up that night. Tried a couple days later Nothing, nothing. It smoked. Then the next try.. I had a runaway starter until I turned the key off. and the relay was smoking like a sailor. The see what happens next. I tried one more time and the bike started.. and was then the relay smelt like smoke. but I couldn't see any smoke.

So is my Solenoid toast? If the shop sold me a relay too small, would it smoke? I believe the original from what I could see was 40AMP. from what I am reading the numbers off the new relay, and it looks to be a 30AMP.

How can you (better where can you) cross-reference Relay part numbers to make sure you have the right relay.

I am new and not good at troubleshooting DC electrical problems.

 

First, make sure your cables from the battery are not internally corroded, and that the ground strap is firmly connected and not corroded. It's not rocket surgery, just a simple solenoid connect to make "big medicine" flow to the starter motor.

The solenoid can fail and be rebuilt if necessary.
https://www.jpcycles.com/product/381...id-rebuild-kit

Good luck, you'll figure it out.

John

 

I have also checked all the Wired connections they all are good clean shape. I just tested the NEW relay... it was FRIED. but the old one I took out is still good. So, I am to the conclusion I need to rebuild the Solenoid. I am thinking about putting the get you home start button.
Are there any opinions as to way not to put on the get you home start button right on the Solenoid?

 

I did find one of the terminals on the starter solenoid (battery to Solenoid) had corrosion. Cleaned that up. Rebuilt the Starter Solenoid.
Now I have a click at the solenoid and a click at the start but doesn't turn over. The battery is at full charge.
Is it time for a new starter? Or am I missing something else that could be tested or fixed?

I did notice that the old plunger had a different ration of room between the copper washer and the "Big" spring and "top" of the plunger. The old one had about 1/8 more travel than the new one. I wasn't sure if that was because of wear? I trusted the rebuild kit I got from Drag Specialties. It did have the gaskets for two different "models" of solenoids.

 

Bench test your starter. The procedures are in the FSM.

 

I figured out the problem. The new solenoid rebuild kit I was sold was for the wrong model. and the Plunger was a wrong fit.

I cleaned up the old plunger with the new electrodes and it fired right off. Now to return the wrong kit and get the correct one.

and I am still able to use the original relay it is in perfect working order. Fun how that get me started working down the chain.

I appreciate everyone's input. this one is a CASE CLOSED.