Buell 2002 X1, Service Manual

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5-12 2002 Buell X1: Electric Starter
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STARTER 5.7
REMOVAL
1
WARNING
1
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
WARNING
1
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 PRIMARY COVER under
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 .
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.
Figure 5-9. Starter Mounting
Figure 5-10. Starter Wires (Protective Boot Not Shown)
Figure 5-11. Free Running Current Draw Test
1
1
2
b0312x5x
1. Mounting Bolts and Washers
2. Starter
6590
1
1. Nut with Washer (metric)
2. Positive Battery Cable Ring Terminal
3. Circuit Breaker Wire Ring Terminal
4. Solenoid Wire
4
2
3
1. Mounting Flange
2. Battery
3. Induction Ammeter
4. Battery Terminal
5. Relay Terminal
b0439x5x
1
4
3
5
2