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Buell Forum » XBoard » Archive through October 19, 2013 » My Buell finally let me down...Input appreciated. « Previous Next »

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50dro
Posted on Saturday, September 07, 2013 - 05:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I started the day off at 9AM looking to put a few hundred miles on my bike and take advantage of the pre-Autumn weather we are currently having in Western PA but it didn't turn out that way...

The last few times I started the bike, it hesitated then ultimately fired up. This morning it did the same so I went about my way thinking that the original 2004 battery was on its last leg. I got about a mile down the road to the gas station where I was meeting ups with my friends, topped off the tank then it simply would not start.

Symptoms:
-Neutral light will not work
-Starter relays click only when clutch is pulled in (even in neutral)
-Bump-starting works (in 5th gear)

So I hunted down a battery up the street and drove the bike there after the bump-start. Old battery was a little weak so I just replaced it figuring the OEM battery had enough. NO CHANGE!!!!

I spoke with a Buell tech at New Castle HD/Buell who walked me through some troubleshooting to test the relays and the starter. Here's what I found:

-The relays send power to the green wire at the starter so they seem OK.
-When testing the green wire (starter signal wire) as it's plugged into the starter, I have constant 12V even when the starter button isn't pushed.
-Testing the wire unplugged from the starter it's only powered when the button is pushed.
-Unplugged the green wire and jumped it to the battery...nothing
-Volt meter to the lead that the green wire plugs into shows 12V (it shouldn't until the button is pressed)

To me, it sounds like there's something messed up inside the starter back-feeding to the signal lead. A new complete starter is pushing $400!

So I figured, F it! I wanted to ride so I bumped the bike again and went down the road. The bike started falling on it's nose between 3-4K RPM. I decided I better not push my luck so I pulled over to turn around. The bike started sputtering and smoking from the intake so I shut her down. Just then a guy pulls up with an empty trailer and was nice enough to get me home. to him! I'm guessing my plugs got fouled from the injectors spraying so many times and all the bump starts etc...I hope that's all it is!

So the bike sits in the garage with the same sad look on its face that I have. That starter is a pain to remove. Looks like you have to pull the whole primary cover to get to it

End of story...Any words of wisdom much appreciated.

PS - Sorry for the long post...
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Greg_e
Posted on Saturday, September 07, 2013 - 08:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes... The starter is actually pretty easy to replace, buy it from Rare Electrical on Amazon or ebay for MUCH less, I have one in my 1050cc XB9R right now.
-Disconnect battery
-Drain gear oil.
-Pull shifter external mechanism and remove clutch cable from side cover, then pull off the clutch actuator arm and ramp.
-remove left side foot peg at the frame for extra room
-Now remove the side cover and watch the rest of the oil drip. Be careful where the shift shaft comes out or you will need a new seal.
-Remove front belt cover to allow access to wiring.
-Remove electrical connections on the starter, you might need to wait until it is loose.
-Remove two bolts holding starter, one of them might be difficult to get on due to the clutch and gear. This is where things might differ, mine is the 9 so your gear may be too big to get the bolts out, but you should be able to get on them and push the starter away from the bolts.
-New starter gasket and put it back in.
-put everything back together, adjust clutch cable and see if it works, then fill with oil.

You should probably have new gaskets for everything, but the only ones I used were starter and side cover. I think the entire job took me about 2 hours and the only "special" tools I needed were allen sockets, ball end would have been easier but I managed to just sneak past the starter gear on the clutch pack.
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Greg_e
Posted on Saturday, September 07, 2013 - 08:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

wrong info - deleted

(Message edited by Greg_E on September 07, 2013)
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Sifo
Posted on Saturday, September 07, 2013 - 08:17 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Be careful where the shift shaft comes out or you will need a new seal.

A couple of wraps of electrical tape around the shaft will help greatly in protecting the seal from damage.
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50dro
Posted on Saturday, September 07, 2013 - 11:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks guys for the great advice! I actually picked up used starter from a part out for $42. Hoping that will do the trick otherwise I'll have to hit up Feebay.

Are the gaskets a HD only part or is there a better source for them?

Thanks again!
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Greg_e
Posted on Saturday, September 07, 2013 - 11:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I got mine from American Sport Bike
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