Hi here BikerChris,
OK, you've already narrowed it down drastically. From your description, I gather that when it does start, the starter is in good order and functioning.
First, the type of clicking:
Rapid, like a machine gun -
Usually indicative of a low battery or excessive draw from the starter. Yes I read your description. I also know I have bought new batteries that were bad off the shelf. Not what's happening here though. The rest of the symptoms don't support it.
A single decisive click and nothing - The solenoid is actuating, but not feeding the starter.
Possible causes: Plating on solenoid scarred, or eroded. Bad contact point in solenoid or starter switch. No connectivity between solenoid and starter.
Here is what may be happening and why:
The solenoid is a really HEAVY DUTY switch. A lot of
Amps
need to pass through it for you starter to turn your engine.
Inside
it are two copper contacts that look like the head of a bolt only
rounded. The battery is attached to one, the starter to the other.
Hovering above them on a spring is a copper clad disk.
When you
turn your key and hit the start button (in a perfect world), an electromagnet is activated that
yanks the disk towards the contacts. When they connect, the circuit is
closed and the starter turns over. OK.
Well, as you can imagine,
each time the disk makes contact, there is a bit of sparkage which can
erode the copper plate on the disc. The reason it IS a disc is that it
rotates a bit each time it connects. This way the contact surface lasts
much longer.
After a while though, you do start to hit bad areas.
That's when it's time to replace it. This is just about the only scenario that causes intermittent solenoid clicking and starter failure with a known good battery.
The same can happen happen with the start switch contacts. If the solenoid actuates, this is not the problem.
Again, that is all dependent
on the battery being fully charged.
The easiest test? Next time it happens, jump it. Jumper cables from a cars battery to yours. If it starts right up, it's the battery or it's connections.
If not, it's the solenoid or it's connections.
I wanted to explain what may be happening and why. It will help with any follow up dialogue we pursue.
'
Best regards
to you
Mike