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STARTER
REMOVAL
1
1
WARNING
WARNING
To protect against accidental start-up of vehicle, discon-
nect the negative battery cable before proceeding. Inade-
quate safety precautions could result in death or serious
injury.
1
1
WARNING
WARNING
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
1.
Remove primary cover. See
6.2 PRIMARY
CHAIN.
2.
See
Figure 5-9.
Remove both starter mounting bolts and
washers (1).
NOTE
A ball hex driver may be required to gain access to the starter
mounting bolts.
3.
See
Figure 5-10.
Remove nut with washer (1) (metric).
a.
Remove protective boot if present.
b.
Remove positive battery cable ring terminal (2).
c.
Remove circuit breaker wire ring terminal (3).
d.
Detach solenoid wire (4).
4.
Remove starter and gasket from the gearcase cover
side.
TESTING ASSEMBLED STARTER
Free Running Current Draw Test
1.
Place starter in vise, using a clean shop towel to prevent
scratches or other damage.
2.
See
Figure 5-11.
Attach one heavy jumper cable (6
gauge minimum).
a.
To the starter mounting flange (1).
b.
To the negative (-) terminal of a fully charged bat-
tery.
3.
Connect a second heavy jumper cable (6 gauge mini-
mum).
a.
To the positive (+) terminal of the battery (2).
b.
To an inductive ammeter (3). Continue on to the bat-
tery terminal (4) on the starter solenoid.
4.
Connect a smaller jumper cable (14 gauge minimum).
a.
To the positive (+) terminal of the battery (2).
b.
To the solenoid relay terminal (5).
5.
Check ammeter reading.
a.
Ammeter should show 90 amps maximum.
b.
If reading is higher, disassemble starter for inspec-
tion. See
5.7
STARTER.
5-12
PRIMARY COVER
under
1.
Mounting Bolts and Washers
2.
Starter
Figure 5-9. Starter Mounting
6590
2
3
1
1.
Nut with Washer (metric)
2.
Positive Battery Cable Ring Terminal
3.
Circuit Breaker Wire Ring Terminal
4.
Solenoid Wire
Figure 5-10. Starter Wires (Protective Boot Not Shown)
b0439x5x
1
4
1.
Mounting Flange
2.
Battery
3.
Induction Ammeter
4.
Battery Terminal
5.
Relay Terminal
Figure 5-11. Free Running Current Draw Test
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.
2002 Buell X1: Electric Starter
5.7
b0312x5x
1
2
1
4
2
5
3
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