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SPECIFICATIONS
5.1
Table 5-1. Starter Specifications
Table 5-2. Service Wear Specifications
STARTER Free speed
3000 RPM (min.) @ 11.5 V
Free current
90 amp (max.) @ 11.5 V
Stall current
400 amp (max.) @ 2.4 V
Stall Torque
8 ft-lbs (11 Nm) (min.) @ 2.4 V
SERVICE WEAR LIMITS
IN.
MM
Brush length (minimum)
0.433
11.0
Commutator diameter (minimum)
1.141
28.981
TORQUE VALUES
ITEM
TORQUE
NOTES
Starter battery positive cable nut
60-85 in-lbs
7-10 Nm
page 5-19
Starter mounting bolts
13-20 ft-lbs
18-27 Nm
page 5-19
2004 Buell Firebolt: Starter
5-1
HOME
ELECTRIC STARTER SYSTEM
5.2
GENERAL
OPERATION
The starter is made up of an armature, field winding assembly, solenoid, drive assembly, idler gear and drive housing.
See Figure 5-1. When the starter switch is pushed, the starter relay is activated and battery current flows into the pull-in winding (10) and the hold-in winding (11), to ground.
The starter motor torque is increased through gear reduction. The gear reduction consists of the drive pinion on the armature, an idler gear and a clutch gear in the drive housing. The idler gear is supported by rollers. The clutch gear is part of the overrunning clutch/drive assembly. The overrunning clutch is the part which engages and drives the clutch ring gear. It also prevents the starter from overrunning. The field windings are connected in series with the armature through brushes and commutator segments.
Wiring Diagrams For additional information concerning the starting system circuit, see the wiring diagram at the end of Section 7, ELECTRICAL.
Starter Relay The starter relay is not repairable. Replace the unit if it fails.
Starter Interlock See 7.5 STARTER INTERLOCK for operation and troubleshooting information.
5-2
2004 Buell Firebolt: Starter
The magnetic forces of the pull-in and hold-in windings in the solenoid push the plunger (7) causing it to shift to the left. This action engages the pinion gear (1) with the clutch ring gear (13). At the same time, the main solenoid contacts (8) are closed, so battery current flows directly through the field windings (3) to the armature (4) and to ground. Simultaneously, the pull-in winding (10) is shorted. The current continues flowing through the hold-in winding (11) keeping the main solenoid contacts (8) closed. At this point, the starter begins to crank the engine. After the engine has started, the pinion gear (1) turns freely on the pinion shaft through the action of the overrunning clutch (12). The overrunning clutch prevents the clutch ring gear (13) (which is now rotating under power from the engine) from turning the armature (4) too fast. When the starter switch is released, the current of the hold-in winding (11) is fed through the main solenoid contacts (8) and the direction of the current in the pull-in winding (10) is reversed. The solenoid plunger (7) is returned to its original position by the return spring, which causes the pinion gear (1) to disengage from the clutch ring gear (13).
HOME
4
b0164a5x
5
3
6 Starter at moment starter switch is closed
2 1 7
8 11
10
12
13 9 Starting circuit-see wiring diagram
4 5
3
6 Starter during cranking
2 1 7
8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Pinion gear Idler gear Field winding Armature Brush Ball bearing Solenoid plunger Main solenoid contacts Battery Pull-in winding Hold-in winding Overrunning clutch Clutch ring gear
11
10
12
13 9 Starting circuit-see wiring diagram
Figure 5-1. Starter Operation 2004 Buell Firebolt: Starter
5-3
HOME
STARTING SYSTEM DIAGNOSIS DIAGNOSTICS
1. 2. 3.
Diagnostic Notes
5.3 Motor terminal Battery terminal Relay terminal
The reference numbers below correlate with the circled numbers on the starter system flow charts. 1. 2.
3
See VOLTAGE DROPS under 5.5 DIAGNOSTICS/ TROUBLESHOOTING.
1
Remove starter motor and connect jumper wires as described in FREE RUNNING CURRENT DRAW TEST under 5.7 STARTER.
2 d0361x5x
3.
Take measurement with connector mated.
4.
See DIAGNOSTICS in 7.5 STARTER INTERLOCK.
5.
See STARTER CURRENT DRAW TEST under 5.6 STARTER SYSTEM TESTING.
6.
See FREE RUNNING CURRENT DRAW TEST.
Figure 5-2. Starter Terminals
Starter Test 1 Check battery using visual inspection, voltage test and load test.
Check connections at battery and starter components. Is system operational? 5822
YES
YES
YES
NO
STARTER RUNS ON.
STARTER SPINS, BUT DOES NOT ENGAGE.
STARTER STALLS OR SPINS TOO SLOWLY.
Check for audible clicking noise.
Disconnect solenoid relay terminal from solenoid. Is 12V present on GN wire with starter button not pressed?
See Starter Test 5: Starter Spins But Does Not Engage.
See Starter Test 6: Starter Stalls or Spins Too Slowly.
Solenoid clicks. See Starter Test 2: Solenoid Clicks.
YES
NO
Is 12V present on starter relay Terminal 86 with starter button not pressed?
Replace solenoid.
OR
Relay clicks. See Starter Test 3: Relay Clicks. 5845
OR NO
YES
Replace right handlebar switchgear. 5818
5-4
2004 Buell Firebolt: Starter
Replace starter relay. 5832
Nothing clicks. See Starter Test 4: Nothing Clicks.
HOME
Starter Test 2: Solenoid Clicks Perform voltage drop tests between battery and relay terminal on solenoid. Less than 1.0 volt?
YES
1
NO
Perform voltage drop tests from battery positive to starter motor terminal. Crank engine. Voltage greater than 1 volt?
21
Backtrack to pinpoint poor connections or relay contact problems using voltage drop tests. 5823
YES
1
NO
Perform voltage drop tests from battery positive to starter battery terminal. Crank engine. Voltage greater than 1 volt?
Perform voltage drop tests between battery negative and starter studs or bolts. Voltage greater than 1 volt?
1
STOP
NO YES
NO
YES
Repair connection between battery and starter.
Repair or replace solenoid (contacts).
Clean ground connections.
5845
Go to Starter Test 3: Relay Clicks. Begin with box marked with bold asterisk.
5824
5824
Starter Test 3: Relay Clicks Test for voltage at solenoid relay terminal on starter. Is 12V present when starter button is pressed?
YES
2
NO
Does starter motor turn if jumped?
*
Test for voltage to relay. Is 12V present on relay terminal 30?
YES
NO
YES
NO
Replace solenoid.
Test starter motor for opens, shorts or grounds. Replace or repair starter motor.
Test for voltage from relay. Is 12V present on relay Terminal 87 when starter button is pressed?
Repair open on R/BK wire feeding Terminal 30 on starter relay.
YES
NO
Repair open on GN wire between relay and solenoid.
Replace starter relay.
5827
5860 5817
5832 5827
2004 Buell Firebolt: Starter
5-5
HOME
Starter Test 4: Nothing Clicks
Check for battery voltage at starter relay Terminal 86 from starter button. Battery voltage present?
YES
NO
Check for ground at relay Terminal 85. Ground present?
3
YES
YES
NO
Substitute Substitute good good starter relay orrelay test or relay. test relay. 5832
4
Inspect Starter Interlock Circuit or Correct Relay Ground.
Check for battery voltage from starter button (BK/R wire at connector [22]). Battery voltage present with starter button pressed?
NO
3
Repair wiring from starter button to relay.
Check for battery voltage to starter button (W/BK wire at connector [22]). Battery voltage present?
5831
5828
YES
NO
Replace right handlebar switchgear. 5816
5-6
2004 Buell Firebolt: Starter
Repair wiring to starter button. 5831
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Starter Test 5: Starter Spins But Does Not Engage
Remove starter. Disassemble drive housing assembly. Inspect for damage to armature gear or idler gear. Damage present?
YES
NO
Replace damaged idler gear and armature.
Starter clutch failure. Replace starter clutch.
5825
5837
Starter Test 6: Starter Stalls or Spins Too Slowly
1
1
Perform voltage drop tests from battery positive to starter motor terminal. Crank engine. Voltage greater than 1 volt?
YES
NO
Perform voltage drop tests between battery positive to starter battery terminal. Crank engine. Voltage greater than 1 volt?
Perform voltage drop tests between battery negative and starter studs or bolts. Voltage greater than 1 volt?
YES
NO
YES
NO
Repair connection between battery and starter.
Repair or replace solenoid (contacts).
Clean ground connections.
Perform starter motor current draw test (on vehicle).
4
Perform starter motor free draw bench test.
5
5835
5845 5824
Are test results within range?
YES
Remove spark plugs while in 5th gear. Rotate rear wheel. Check for engine, primary and/or crankshaft bind. Use appropriate code
NO
Test starter motor for opens, shorts or grounds. Replace or repair starter motor. 5817
2004 Buell Firebolt: Starter
5-7
HOME
STARTER ACTIVATION CIRCUITS
5.4
b0157a5x
0.1A
0.1A
5 4
ITEM A
0.1A
0.1A
6
0.1A
0.1A
0.1A
0.1A
5
7
9
4
0.1A
8
IDEAL CLOSED CIRCUIT
6 7
0.1A
0.1A
20A
ITEM B
0.1A
0.1A
9 0.1A
8 20A
10 0.1A
10 0.1A
3
3 OV
20A 15A
20A
15A VDC
2 1
11
150A
12
11
2 1
150A
150A
150A
ITEM C
0.1A
0.1A
5 4 0.1A
GROUND CIRCUIT 0.1A
0.1A
6
0.1A
0.1A
5
7 0.1A
ITEM D
OPEN CIRCUIT
0.1A
0.1A
9
8
4
0.1A
20A
0.1A
0.1A
3
0.1A 12V
VDC
1. 2. 3. 4. 5.
8
3
20A
10
OV
20A
150A
11 150A
6.
Battery Main fuse (30 A) Key switch fuse Key switch Run/Stop switch
7. 8. 9.
12
11
2 1
Ignition relay (used for junction purposes only) Ignition fuse Key switch relay Start switch
150A
10. Start relay 11. Solenoid 12. Starter
Figure 5-3. Typical Circuity. Refer to wiring diagrams for more information.
5-8
9
15A
2 1
0.1A
VDC
20A
15A
6 7
10 0.1A
12
2004 Buell Firebolt: Starter
150A
12
HOME
DIAGNOSTICS/TROUBLESHOOTING GENERAL
5.5
6.
Typically, a good circuit will drop less than 1 volt.
7.
If the voltage drop is greater, back track through the connections until the source of the potential difference is found. The benefit of doing it this way is speed.
Follow the 5.3 STARTING SYSTEM DIAGNOSIS diagram to diagnose starting system problems. The VOLTAGE DROPS procedure below will help you to locate poor connections or components with excessive voltage drops.
a.
Readings aren’t as sensitive to real battery voltage.
b.
Readings show the actual voltage dropped, not just the presence of voltage.
VOLTAGE DROPS
c.
Check the integrity of all wiring, switches, fuses and connectors between the source and destination.
This tests the system as it is actually being used. It is more accurate and will display hard to find poor connections.
d.
This approach can be used on lighting circuits, ignition circuits, etc. Start from most positive and go to most negative (the destination or component).
The voltage drop test measures the difference in potential or the actual voltage dropped between the source and destination. 1.
See ITEM A in Figure 5-3. Attach your red meter lead to the most positive part of the circuit, which in this case would be the positive post of the battery (1).
2.
See ITEM B in Figure 5-3. Attach the black meter lead to the final destination or component in the circuit (solenoid terminal from relay).
3.
Activate the starter and observe the meter reading. The meter will read the voltage dropped or the difference in potential between the source and destination.
4.
An ideal circuit’s voltage drop would be 0 volts or no voltage dropped, meaning no difference in potential.
5.
See ITEM C in Figure 5-3. An open circuit should read 12 volts, displaying all the voltage dropped, and the entire difference in potential displayed on the meter.
8.
See ITEM D in Figure 5-3. The negative or ground circuit can be checked as well. a.
Place the negative lead on the most negative part of the circuit (or the negative battery post). Remember, there is nothing more negative than the negative post of the battery.
b.
Place the positive lead to the ground you wish to check.
c.
Activate the circuit. This will allow you to read the potential difference or voltage dropped on the negative or ground circuit. This technique is very effective for identifying poor grounds due to powdered paint. Even the slightest connection may cause an ohmmeter to give a good reading. However, when sufficient current is passed through, the resistance caused by the powdered paint will cause a voltage drop or potential difference in the ground circuit.
2004 Buell Firebolt: Starter
5-9
HOME
IGN SW
bd0023xx
IGN LOCK
5-10 RH CONTROLS
[33A]
STARTER SOLENOID
IGNITION SWITCH WIRING DIAGRAM
R
1 2 3 4 1 2 3 4 R/BK R
[22A]
BK/R W/BK W/BK GY/O
2004 Buell Firebolt: Starter
1 2 3 4
[33B]
KEY POSITION
A
PARK
0
C
BK B
D
[128A]
BK
0
LOCK
1 GN
[GRD2]
ON
0
0
0
0
WIRE COLOR
R
R/BK
R
R/GY
1
1
1
1
WIRE SECT mm CONNECTING
+ BATTERY USER +
R/Y
OFF
GROUND
+ BATTERY USER +
FUSE/RELAY ASSEMBLY
[61B]
BATTERY R/Y TN/Y
41 40
35
R
34
TN/LT.GN
DIODE
IGNITION GY/O
27
21
44
KEY SWITCH 38
R
R/BK
R
NEUTRAL SW TN/Y [131B]
[62B]
1 2 4 5 3
10 2 6 8 7
1 2 4 5 3
11 19 15 13 14
W/BK W/BK BK GY/O GY/O
BK/R TN/LT.GN R/BK GN R/BK
TN/LT.GN BK
IGNITION
1 9 5 3 4
KEY SW
1 2 4 5 3
START
FUSE/RELAY ASSEMBLY
[95B]
1 2
CLUTCH SW
BK R R/BK
Figure 5-4. Electric Starting System Circuit
1
1 [131A]
[128B]
