I recently took on the starter click issue.
Upgrading cables, starter motor, cleaning posts etc. helped reduce the problem but did not 100% fix it.
For me the only thing that made a big difference was filing down the pitted and corroded solenoid contacts.
I have a rebuild kit on the shelf and if it starts the click again; I'll use the new parts. After a few weeks of perfect operation, I expect it will be a while before I need it.
I do like the 1.4 motor and would recommend replacing the motor and solenoid parts at the same time.
You CAN get the starter off without dropping the pipes.
Remove the starter motor first, being careful that the armature doesn't hang up in the housing. If it slips out of the brushes at the rear; the motor won't clear the crossover. Don't ask me how I know.
After the motor is out there's plenty of room to get the housing.
Well bike is all fixed, the kit arrived and I managed to remove the starter without having to take the pipes off...came out easily, but may be more difficult with standard cat fitted.... This was an easy fix and took around half an hour once the starter was on the bench. Ive uploaded a couple of pics of the kit and where it goes incase anyone wanted a look at it.
I have read through that thread but am not sure what starter to order in Aus.
EVery now an then mine will do the click thing and at times feels a little tired starting up.
Was after someone in Aus who has ordered one here that I could hear from.
Any time I have tried ordering parts for cars they want the VIN and in this case I just want the correct part, to use on a bike!
@GaryA I suppose there is a different part number there, but I bet the part is the same as that mentioned in the opening thread.
Most of my starter problems come frim me being lazy and not keeping the machine clean. I ride in all sorts if rain and road salt/grime gets everywhere causing parts to corpse earlier than others. Replacing battery cables with newer and better ones goes along way too.
All the tips like upgrading the cables (I used 2/0 welding cable), cleaning all the connections, and cleaning or replacing the solenoid contacts are good suggestions, however, the only true permanent fix is the Toyota Celica or Toyota Tacoma starter (best price at RockAuto.com) coupled with an EarthX Lithium Iron Phosphate battery (expensive, but worth every penny of confidence and serenity). I have 86,000 miles on my Rocket and was plagued with starter issues for the first 50,000. The upgraded starter and battery have provided 36,000 miles of trouble free starts. I have TOR's and cat-delete pipe. This upgrade is relatively easy and straight forward. Just do it.