Buell X1 2002 Service Manual page 344

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RUN-ON
Disconnect Solenoid
"Relay" Terminal from
Solenoid. Is 12V Present
at GN Wire Terminal with
Starter Button NOT
Pressed?
YES
Is 12V Present on
Starter Relay Terminal
86 with Starter Button
NOT Pressed?
YES
Replace Right
Handlebar
Switchgear.
5818
Remove starter motor and connect jumper wires as described in
1
RUNNING CURRENT DRAW TEST
See VOLTAGE DROPS.
2
See STARTER CURRENT DRAW TEST
3
TESTING.
4 See FREE RUNNING CURRENT DRAW
5 See DIAGNOSTICS in 7.5 STARTER
5-6
STARTER SPINS, BUT
DOES NOT ENGAGE
Disassemble Drive
Housing Assembly.
Inspect for Damage
to Armature Gear or
NO
Idler Gear. Damage
Replace
Solenoid.
5845
NO
Replace Starter
Relay.
5832
STARTER STALLS OR
SPINS TOO SLOWLY
Perform Voltage Drop
2
Tests from 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 "Battery" Terminal.
Crank Engine. Is Voltage
Greater than 1 Volt?
YES
Repair Connection
Between Battery
and Starter.
5824
NOTES
under 5.7 STARTER.
under
TEST.
INTERLOCK.
Figure 5-3. Starting System Diagnosis, Part 2
Remove Starter.
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
5.6 STARTER SYSTEM
5837
NO
3
Perform Starter Motor
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.
2002 Buell X1: Electric Starter
NO
5817