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Join Date: Jul 2006
Location: Kennett Square, PA
Gosh, just reading your post gives me PTSD symptoms.
Ok, if you have the click, your starter relay is working, but since it's not even trying to start, sounds like an electrical issue (esp. with your tach going nuts). A couple of things to check that are very likely culprits include:
1. Electrical connections in the ignition circuit - make sure to double-check all ground wires, especially.
2. The order of the washers on your starter motor lead - from the case, it should be insulated washer, copper washer, positive lead from the relay, regular ol' washer, and then the nut. Make sure the metal on the lead isn't touching any part of the case or you've grounded it out and all power is going to your...well, frame.
3. Test all of your electrical components - do you have turn signals? Brake light works? How about your fuel gauge? Gauge lights? Headlight? etc. Since the "foot bone's connected to the leg bone" (electrically speaking), you may find that some other electrical component isn't working.
4. Do you know your starter works? Did you test it off the bike? If not, you can drain the oil, pull the starter motor, and bench test it to make sure it's good.
5. Battery voltage is good? Got enough juice to kick the starter motor over? If you're not sure, take it to Pep Boys or someplace similar and have them check it.
Start there and let us know what your results are. Troubleshooting after a rebuild is pure-T Heck...so go slowly, methodically, and keep notes of everything you've done so that you can have a good record of steps taken.