Buell X1 2002 Service Manual page 342

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SOURCE OF
PROBLEM
1. Starter does not Battery.
run or runs at very
low speeds.
Wiring.
Starting switch or
starter relay.
Solenoid.
Starting motor.
2. Pinion does not Battery.
engage with ring
gear while starter is
running or engine
cannot be cranked.
Wiring.
Overrunning
clutch.
Ring gear.
3. Starter does not Solenoid.
stop running.
Starting switch or
starter relay.
5-4
Table 5-1. Troubleshooting
PROBABLE CAUSE
PROBLEM
Voltage drop due to discharged battery.
Short-circuited or open between elec-
trodes.
Poor contact condition of battery termi-
nal(s).
Disconnection between starter switch
and solenoid terminal.
Malfunction in starter interlock system.
Poor contact condition or poor connec-
tion.
Poor contact condition caused by burnt
contact.
Contact plate removed.
Pull-in winding open or short-circuited.
Hold-in winding open.
Poor contact condition of brushes.
Commutator burnt.
Commutator high mica.
Field winding grounded.
Armature winding grounded or short-
circuited.
Reduction gears damaged.
Insufficient brush spring tension.
Disconnected lead wire between sole-
noid and field windings.
Ball bearing sticks.
Voltage drop due to discharged battery.
Short-circuited or open between elec-
trodes.
Poor contact condition of battery termi-
nal(s).
Disconnection between starter switch
and solenoid terminal.
Overrunning clutch malfunction (rollers
or compression spring).
Pinion teeth worn out.
Pinion does not run in overrunning
direction.
Poor sliding condition of spline teeth.
Reduction gears damaged.
Excessively worn teeth.
Return spring worn.
Coil layer shorted.
Contact plate melted and stuck.
Unopened contacts.
Poor returning.
SOLUTION
Charge battery.
Replace battery.
Clean and retighten.
Repair or replace wire.
See 7.5 STARTER INTERLOCK.
Replace.
Polish contact surface or replace
solenoid assembly.
Repair.
Replace solenoid assembly.
Replace solenoid assembly.
Check brush spring tension.
Correct on lathe or replace.
Correct by undercutting.
Replace.
Replace.
Replace.
Replace.
Repair or replace lead wire.
Replace bearing.
Charge battery.
Replace battery.
Clean and retighten.
Repair or replace wire.
Replace overrunning clutch.
Replace overrunning clutch.
Replace overrunning clutch.
Remove foreign materials, dirt, or
replace overrunning clutch.
Replace overrunning clutch and idler
gear.
Replace ring gear.
Replace solenoid.
Replace solenoid.
Replace solenoid.
Replace starting switch or starter
relay.
Replace starting switch or starter
relay.
2002 Buell X1: Electric Starter