Recheck all the electrical connections. Might be a corroded/slightly loose connection, especially a bad ground at the frame.

 

i agree that it sounds electical. members here have removed or disabled the ACR with no effect on starting with the elec start. the ACR is really only there for the kickstarter IMO.

 

11.5 v at the battery and 9 v at the starter. Checked a friends bike and it's about the same. Does that sound normal guys?

 

No, that seems like a big voltage drop just across the cables and solenoid.

If you've tried it with a fresh, well charged battery then I'll bet you've got a bad connection or a bad starter solenoid.

While cranking, measure the voltage at -
1) positive terminal of battery
2) battery side of starter solenoid
3) starter motor side of solenoid
4) starter motor

1) is already OK at 11.5V

If 2) is low, check the cable connection at the battery and at the battery side of the solenoid for corrosion and tightness. Disconnect the negative terminal while doing this so you don't arc anything.

if 3) is low and 2) ok, your solenoid is bad.

if 1), 2), and 3) are good, check the cable connection at the starter side of the solenoid and at the starter for corrosion and tightness.

Also do what Brewster said and make sure your ground to the battery is good. Measure voltage from the starter housing (not cable) to the negative terminal of the battery while cranking. It should zero. If not, you've got a bad ground.

 

Can't you run a hot line direct from battery to starter to test if it spins over better after bypassing the starter solenoid?

 

9v might work if you measured it while actually cranking the engine....otherwise there is s HUGE loss going on somewhere between the battery and the starter terminal. A battery with the key in the ON position isn't great at 11.5 volts. Key off minimum would be 12.5V...unless you had just applied a load to it in the last while

 

I swapped over the starter relay to a new one and it made no difference :/

 

did you try another batterY?
If it is not that your starter windings may be shorted, clean the armature!

 

Yep it's a new battery and it's low because I've been turning it over a lot to show people/make a video

 

I've also taken the starter off and cleaned it... put it on another bike and it works fine!