Buell 2005 P3 Service Manual page 295

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RUN-ON
Disconnect solenoid "Relay"
terminal from solenoid.
Is 12V present at GN wire ter-
minal with starter button
NOT pressed?
YES
Is 12V present on starter
relay terminal 86 with
starter button NOT
pressed?
YES
Replace right
handlebar
switch gear.
5818
STARTER STALLS OR SPINS TOO SLOWLY
1. Remove starter motor and connect jumper wires as described in
RUNNING CURRENT DRAW TEST
2. See VOLTAGE DROPS.
3. See STARTER CURRENT DRAW TEST
TESTING.
4. See FREE RUNNING CURRENT DRAW
5. See diagnostics in 7.11 STARTER/IGNITION
5-6 2005 Buell P3: Electric Starter
STARTER SPINS, BUT DOES NOT ENGAGE
Remove starter. Disassemble
drive housing assembly. Inspect
for damage to armature gear or
NO
Replace
Solenoid.
5845
NO
Replace
starter relay.
5832
Perform Voltage Drop Tests from
2
battery (Pos. +) to starter
"Motor" terminal.
Crank engine.
Is voltage greater than 1 volt?
YES
2
Perform Voltage Drop Tests from
battery (Pos. +) to starter
"Batter y" terminal.
Crank engine.
Is voltage greater than 1 volt?
YES
Repair connection
between battery and
starter.
5824
NOTES
under 5.7 STARTER.
under 5.6 STARTER SYSTEM
TEST.
INTERLOCK.
Figure 5-3. Starting System Diagnosis, Part 2
idler gear.
Damage present?
NO
YES
Replace Starter clutch
damaged gear failure. Replace
and armature. starter clutch.
5825
NO
Perform Voltage Drop Test
between battery (Neg. -) and
starter studs or bolts.
Is voltage greater than 1 volt?
YES
NO
Clean ground
connections.
Repair or
replace
5835
solenoid
(contacts).
4
5845
FREE
5837
NO
Perform starter motor
3
current draw test
(on vehicle).
Perform starter motor
Free Draw Bench Test.
Are test results in range?
YES
Inspect engine or Test starter motor
primary drive. for Opens, Shorts
or Grounds.
Replace or repair
starter motor.
NO
5817