Buell 2003XB9S Service Manual page 442

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Starter Test 5: Starter Spins, But Does Not Engage
Starter Test 6: Starter Stalls or Spins Too Slowly
YES
1 Perform voltage drop tests
between battery positive to
starter battery terminal.
Crank engine.
Voltage greater than 1 volt?
YES
Repair connection
between battery and
starter.
5824
Remove starter. Disassemble drive housing
assembly. Inspect for damage to armature
gear or idler gear. Damage present?
YES
Replace damaged idler
gear and armature.
5825
Perform voltage drop tests from battery
1
positive to starter motor terminal. Crank
engine. Voltage greater than 1 volt?
NO
Repair or replace
solenoid (contacts).
5845
NO
Starter clutch failure.
Replace starter clutch.
between battery negative and
YES
Clean ground Perform starter motor current
connections.
5835
Perform starter motor free draw
Are test results within range?
YES
Remove spark plugs while in
5th gear. Rotate rear wheel.
Check for engine, primary
and/or crankshaft bind.
Use appropriate code
2003 Buell XB9S: Starter
5837
NO
Perform voltage drop tests
starter studs or bolts.
Voltage greater than 1 volt?
NO
4
draw test (on vehicle).
5
bench test.
NO
Test starter motor for
opens, shorts or grounds.
Replace or repair starter
motor.
5817
5-7