My 2001 XLT1200 won't start, took it out on weekend and it ran sweet allday. Then all of a sudden it would not start. The starter motor won't engage. Battery is fine. The elctric box makes a clicking noise when you push the start button but starter motor does not engage. Got it home and it started first go, numerous times. But now it won't start again.
Any ideas??? I thought loose wire, but all seems good.
Mate, it could be the starter relay. That is what you are hearing making the clicking noise. Sometimes the contacts get covered in carbon (from the high instantaneous current demand every time you hit the start button), this ends up preventing the contacts from 'making proper contact'. Unfortunately, in most watercraft, this is a sealed unit (for obvious reasons) so you can't open it and clean it. The next time it makes the clicking sound and does not turn over, pop the lid off the box and short the two terminals across the relay (the terminals with two large red wires connected to them). One of the red wires connects to the battery and the other to the starter motor. If it turns over, then the solenoid/relay needs replacing.
Oh, by the way, when you short across the relay (use a screwdriver) it will arc like a bastard, be careful not to fill your daks (when I do it, I know it is going to happen and I still sh1t myself none the less). Make sure you make good firm contact on the terminals. You will not get an electric shock (voltage too low).
Good luck mate, let us know how you go.
I don't suffer from insanity, I enjoy every minute of it!
If you need a whole new starter i recommend www.db-starter-alternator.com they have a ebay site and are really helpful and cheap.
jetpower & freo yamaha wanted like $800+ for a genuine 701 starter, i got it through these guys for $90 + $70 postage, took 5 days delivery. BRAND NEW !!
Xlt1200 Won't Start 
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