Testing Starter On Bench; Free Running Current Draw Test; Starter Solenoid; Solenoid Pull-In Test - Buell 2008 XB SERIES Electrical Diagnostics Manual

TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST

1. Remove starter from motorcycle in accordance with the
procedures in the Service Manual.
2. Place starter in vise, using a clean shop towel to prevent
scratches or other damage.
3. See Figure 1-12. Attach one heavy jumper cable (6 gauge
minimum).
a. Connect one end to the starter mounting flange (1).
b. Connect the other end to the negative (-) terminal of
a fully charged battery (2).
4. Connect a second heavy jumper cable (6 gauge minimum).
a. Connect one end to the positive (+) terminal of the
battery (2).
b. Connect the other end to the battery terminal (4) on
the starter solenoid. Place an inductive ammeter (3)
over cable.
5. Connect a smaller jumper cable (14 gauge minimum).
a. Connect one end to the positive (+) terminal of the
battery (2).
b. Connect the other end to the solenoid relay terminal
(5).
6. Check ammeter reading.
a. Ammeter should show 90 amps maximum.
b. If reading is higher, disassemble starter for inspection.
See the Service Manual.
c. If starter current draw on vehicle was over 200 amps
and this test was within specification, there may be a
problem with engine or primary drive.
1-22 2008 Buell XB Diagnostics: Starting / Charging
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1
4
5
1. Mounting flange
2. Battery
3. Induction ammeter
4. Battery terminal
5. Relay terminal
Figure 1-12. Free Running Current Draw Test

STARTER SOLENOID

Do not disassemble solenoid. Before testing, disconnect field
wire from motor terminal as shown in
Each test should be performed for only 3-5 seconds to prevent
damage to solenoid.
The solenoid Pull-in, Hold-in, and Return tests must be per-
formed together in one continuous operation. Conduct all three
tests one after the other in the sequence given without interrup-
tion.

SOLENOID PULL-IN TEST

1. See Figure 1-13. Using a 12-volt battery, connect three
separate test leads as follows:
a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.
2. Observe starter shaft.
a. If starter shaft extends strongly, solenoid is working
properly.
b. If starter shaft does not extend strongly, replace the
solenoid.
1.8
2
3
Figure 1-13.