305CSR won't start HELP!

Ok guys... I need help. I pulled my head off to reseal gaskets/check internals. I got everything back together and the bike won't even turn over. It just clicks like it has a dead battery... but the battery is brad new and registers 12v. This was not a problem before I disassembled it. I checked the fuses and all are good. The starter was just rebuilt so I don't think it could be that. I can turn the motor over by hand, but its almost like the starter can't turn it over. Any suggestions please?!?

Try jumping across the heavy gauge terminals on the starter solenoid with a pair of pliers or screwdriver(it will throw a spark so be careful around gas or flamable fluids).

If the bike still won't turn over, something is bound up either in the starter or the starter clutch mechanism.

Thanks for the help... I'm starting to think it is the battery because it reads 12v and when you push the start button it drops to ~6v. I took of the side cover (stator cover?) and the starter spins free when there is no load. I did get it to start with the side cover off though... ran it for about 3 minutes and it died... then the battery read ~10v. So, I'm going to assume it may be the battery.

I'd try to get a quality battery if I could. All battery cables must be clean and tight for maximum current flow including the ones going to and from the starter solenoid.

Don't forget the Negative(-) one from the battery terminal to the engine mounting bolt.

6 gauge welding cable makes a great ground cable. And go to a battery shop to have the correct sized terminals crimped on.

Ok, I got a new battery, and that wasn't the problem. The starter is completely un-responsive. I took it apart, cleaned it, and reassembled it... I hooked it up to my 12v battery charger and it spun sluggishly for about 30 seconds and then slowed to a stop... and that was it.

The battery is at ~12.7v there is ~11.5v at the starter and over 100A... I'm guessing the starter is just dead?

Look here for starter rebuild kits: www.cyclewareables.com/pages/street_star...kits/startmtrkit.htm

you have a boot starter on that bike?

Thanks for the info on rebuild kits...

By "boot starter" do you mean kick start? if so, then no... the bike has no kick start.

yeah, a kicker, hmmmmm I can see why your so concerned now. Good luck!

Ok guys... I got a working starter finally! The battery is brand new, but I'm still having a problem...

Its like something is binding... The new (working) starter spins strong and freely when it is disconnected from motor, but when its all hooked up, it will occasionally grunt the engine over once... and then just click after that. Any ideas?

Most starters have bushings instead of bearings where the shaft rotates. The bushing may be worn beyond use. Also check for end play or movement from side to side when it is energized. It might be moving enough to make poor contact with the brushes.

Ask around at the electric motor rebuild places in town. They should be able to help you, or at an automobile starter rebuild shop.

I dont think the starter motor is to blame... because this is the 2nd starter, and the same problem. Eliminating the starter motor and battery, what is left?

The solenoid? Would the solenoid still spin the starter motor under no load if it was bad?