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Old 12-26-2011, 06:17 PM   #1 (permalink)
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Default 2000 xl1200 limited electrical issue

I just rebuilt the top end of my XL1200L, bought it with the engine seized, piston 3 had locked. I put everything together by the book, engine compartment looked great, clean, and well maintained. Hull has 179 hrs. When I try to start it, all I hear is a click coming from the starter solenoid inside the electrical box. I opened the box, everything looks like new. I bypassed/bridged the solenoid and the engine turns freely, the starter sounds strong. Also, an alarm goes off when I hit the start button and the dash reads 'start'. Previous owner did not know engine was seized and had replaced solenoid with a new one thinking that was the problem. I tried another solenoid thinking he had burned the one he installed and all I got was a buzz, no turning of engine. I do not know a lot about electric/electronic trouble shooting for this machine, any help will be very appreciated...
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Old 12-26-2011, 09:14 PM   #2 (permalink)
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If it will turn when you jump the solenoid, but not otherwise, then you have a bad solenoid.
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Old 12-30-2011, 05:17 PM   #3 (permalink)
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So if you jump the leads of the solenoid the engine cranks, did you check the lead coming from the start button? If the current from the starter switch is weak or shorted, the relay will bounce or not work at all.
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