2007 Buell Lightning: Starter 5-11
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STARTER SYSTEM TESTING 5.6
“ON-MOTORCYCLE” TESTS
Starter Relay Test
NOTE
Starter relay test also applies to ignition and key switch
relays.
1. See Figure 5-5. Locate starter relay. The relay is
attached to the relay block under the seat.
2. To test relay, proceed to Step 3. If installing a
new
starter
relay, remove old relay. Install
new
relay into relay block.
3. See Figure 5-6. Obtain a 12 volt battery and a continuity
tester or ohmmeter.
a. Pull relay from relay block.
b. Connect positive battery lead to the 1 terminal.
c. Connect negative battery lead to the 2 terminal to
energize relay.
d. Check for continuity between the 3 and 5 terminals.
A good relay shows continuity (continuity tester lamp
“on” or a zero ohm reading on the ohmmeter). A
malfunctioning relay will not show continuity and
must be replaced.
4. If starter relay is functioning properly, proceed to
STARTER CURRENT DRAW TEST.
Starter Current Draw Test
NOTES
●
Engine temperature should be stable and at room tem-
perature.
●
Battery should be fully charged.
See Figure 5-7. Check starter current draw with an induction
ammeter before disconnecting battery. Proceed as follows:
1. Verify that transmission is in neutral. Disconnect spark
plug wires from spark plug terminals.
2. Clamp induction ammeter over positive battery cable
next to starter.
3. With ignition key switch ON, turn engine over by pressing
starter switch while taking a reading on the ammeter.
Disregard initial high current reading which is normal
when engine is first turned over.
a. Typical starter current draw will range between 140-
180 amperes.
b. If starter current draw exceeds 180 amperes, then
the problem may be in the starter or starter drive.
Remove starter for further tests. See 5.7 STARTER.
Figure 5-5. Relay Block (top view)
Figure 5-6. Starter Relay Test
Figure 5-7. Starter Draw Test
Spare
Diode
Bk/Hn/Mflr
Fan
Battery
IGN
15A
15A
10A
10A
10A 10A
15A
10A
15A
30A
Acces.
Key Switch
Lights
ECM
Spare
ISO
ISO
ISO
KEY SW
IGNITION
START
87
86
87A
85
30
Battery
Induction
Ammeter
b0160x5x
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