2007 Buell Lightning: Starter 5-13
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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 5-10. 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.
Starter Solenoid
NOTES
●
Do not disassemble solenoid. Before testing, disconnect
field wire from motor terminal as shown in Figure 5-11.
●
Each test should be performed for only 3-5 seconds to
prevent damage to solenoid.
●
The solenoid Pull-in, Hold-in, and Return tests must be
performed together in one continuous operation. Con-
duct all three tests one after the other in the sequence
given without interruption.
Solenoid Pull-in Test
1. See Figure 5-11. Using a 12 volt battery, connect three
separate test leads as follows:
a. Solenoid housing to negative battery post.
b. Solenoid motor terminal to negative battery post.
c. Solenoid relay terminal to positive battery post.
2. Observe starter pinion.
a. If starter pinion pulls in strongly, solenoid is working
properly.
b. If starter pinion does not pull in, replace the sole-
noid.
Figure 5-10. Free Running Current Draw Test
Figure 5-11. Pull-In Test
1. Mounting flange
2. Battery
3. Induction ammeter
4. Battery terminal
5. Relay terminal
b0439x5x
1
4
3
5
2
Battery
b0161a5x
Motor terminal
Relay terminal
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