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Duing my unsuccessful attempts to start my Tbird, the battery is transmitting power to the solenoid (I hear a click), however the engine doesn't turn over. My buddy checked the electronics and its flowing to the solenoid and through the starter.
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Just because the starter solenoid clicks doesn't mean it's switching full battery power to the starter.
Inside the solenoid there's a coil of wire and an iron 'core' rod with a spring on the bottom and a washer on the top. When you press the starter button the magnetic field generated in the coil pulls the core down into the center of the coil.
What should happen then is that the 'washer' makes contact between the two large terminals on the top of the solenoid.
There are several mechanical failures possible that might prevent full travel of the core but most likely the contact areas on the 'washer' have burned to the point that they're not making a good, low resistance contact.
You can short across the large terminals on the solenoid with a screwdriver to test the contacts, but be VERY sure the bike is in neutral and the clutch is pulled in or it will roll forward -- usually right off the kickstand and into an expensive pile. If the starter cranks properly with the big terminals shorted together then it's most probably time to replace the solenoid.
You can also use a voltmeter to test the solenoid. With the start button NOT pushed, you should read the battery voltage across the big terminals. When you press the starter button that voltage should ideally drop to zero. If the starter is cranking and you're reading 1 volt or more across the solenoid terminals, I'd replace the solenoid.
It's also possible that the starter button or solenoid primary terminals are dirty or corroded and not supplying enough power to the solenoid coil to fully engage it, so if shorting the big terminals works then it's time to check the rest of the starting circuit.
Another possibility (and my personal favorite) is that the battery terminals and/or cable ends are corroded, so disconnect them, wire brush them until shiny, and put them back together with a healthy layer of grease to keep them from corroding again.
I'd be surprised if the starter motor is already worn out on a 2003 bike, but the starter could be full of oil or have a sticking or broken brush. That's probably the last thing to look at after the battery terminals and solenoid test.
Jim
