Figure 5-3. Starting System Diagnosis, Part 2
STARTER SPINS, BUT
DOES NOT ENGAGE
Perform Voltage Drop
Tests from Battery (Pos. +)
to Starter “Motor” Terminal.
Crank Engine. Is Voltage
Greater than 1 Volt?
Test Starter Motor
for Opens, Shorts
or Grounds.
Replace or Repair
Starter Motor
Starter Clutch
Failure. Replace
Starter Clutch.
Replace
Damaged Gear
and Armature.
RUN-ON
Inspect Engine or
Primary Drive.
Perform Starter Motor
Free Draw Bench Test. Are
Test Results in Range?
Perform Starter Motor
Current Draw Test (on
Vehicle).
STARTER STALLS OR
SPINS TOO SLOWLY
Disconnect Solenoid
“Relay” Terminal from
Solenoid. Is 12V Present
at GN Wire Terminal with
Starter Button NO
T
Pressed?
Is 12V Present on
Starter Relay Terminal
86 with Starter Button
NO
T Pressed?
Replace Right
Handlebar
Switchgear.
Replace Starter
Relay.
Replace
Solenoid.
YES
NO
NO
YES
NO
NO
YES
Perform Voltage Drop Test
Between Battery
(Neg. -) and Starter Studs
or Bolts. Is Voltage Greater
than 1 Volt?
Clean Ground
Connections.
NO
YES
Perform Voltage Drop
Tests from Battery (Pos. +)
to Starter “Battery” Terminal.
Crank Engine. Is Voltage
Greater than 1 Volt?
YES
NO
Repair Connection
Between Battery
and Starter.
Repair or
Replace
Solenoid
(Contacts).
YES
2
3
4
2
NOTES
Remove starter motor and connect jumper wires as described in FREE
RUNNING CURRENT DRAW TEST under 5.7 STARTER.
See VOLTAGE DROPS.
See STARTER CURRENT DRAW TEST under 5.6 STARTER SYSTEM
TESTING.
See FREE RUNNING CURRENT DRAW TEST under 5.7 STARTER.
See DIAGNOSTICS in 7.6 STARTER INTERLOCK.
Continued from
Previous Page
Remove Starter.
Disassemble Drive
Housing Assembly.
Inspect for Damage
to Armature Gear or
Idler Gear. Damage
Present?
YES
NO
1
2
3
4
5
5818
5832
5825
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5824
5845
5835
5817
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