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Sparkplug90
Posted on Sunday, May 11, 2014 - 09:35 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I've been having trouble getting my 97 buell s1 lightning to start. When I try to turn the bike over the starter just makes a strong clicking/chattering noise. I replaced the battery, then replaced the starter relay thinking that might be where I'm getting the voltage drop. It seems that there is not enough juice getting to the starter to crank it. Is there a way I can check the solenoid? I pulled out the solenoid plunger the other day and wiped it off. But I was staring at it without an idea of what to check. The bike runs good, charges good, and has a good battery, and clean connections to the battery. It just won't crank. Any ideas? Is it a bad solenoid? If so how do I clean it up to get good current through it again?
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Buell_bert
Posted on Sunday, May 11, 2014 - 01:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ground to the frame??
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Buell_bert
Posted on Sunday, May 11, 2014 - 01:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ground to the frame?? Not just tight but take it off and clean it. Let us know how it goes.
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Sparkplug90
Posted on Monday, May 12, 2014 - 09:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok, so I cleaned the ground to the frame, and then cross checked it with a test lamp, still clicks.
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Buell_bert
Posted on Monday, May 12, 2014 - 01:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Voltage drop across the starter switch/button. Contacts old/dirty?
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Jim2
Posted on Wednesday, May 14, 2014 - 08:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The solenoid has a big copper washer that makes contact with two copper terminal pieces when it get sucked in. This contact interface between the plunger and the two contacts (when it's sucked in) is what conducts the current. The two contacts and the washer all wear over time and they wear uneven. This reduces the amount of surface contact. Look for uneven wear.

http://www.badweatherbikers.com/cgibin/discus/disc us.cgi?pg=next&topic=47623&page=265543
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Sparkplug90
Posted on Thursday, May 15, 2014 - 10:27 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok, I checked the starter switch button and it was good. I've got a solenoid rebuild kit on the way. I'm thinking to get the starter off I'll have to remove at least the primary outer cover. And possibly the primary chain & inner cover. Are there any gaskets kits I should order and replace while I'm in there? This will be the first time I've opened one of these up.
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Jim2
Posted on Thursday, May 15, 2014 - 03:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You do not need to remove the whole starter to install the starter solenoid rebuild kit. Disconnect the battery. From the right side of the bike you can just remove the three screws that hold on the back plate over the solenoid part of the starter. The back plate and rubber gasket will come off and then the plunger will pull out. The terminals unscrew from the sides and remove from inside the solenoid housing.

Where did you get your rebuild kit?
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Sparkplug90
Posted on Monday, May 19, 2014 - 09:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I got it on ebay from catalyst cycles in Tennessee. I got it in today, hopefully I can get some time this week to rebuild it and let y'all know how it goes.
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Sparkplug90
Posted on Friday, May 23, 2014 - 10:45 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok, I completely rebuilt the solenoid. I found out that the rapid clicking noise going on was the plunger in the solenoid rapidly bouncing (plunging) back and fourth. Still not turning over or getting the starter to crank. So should my next step be to remove the starter to go get it tested?
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Jim2
Posted on Sunday, July 06, 2014 - 02:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Did you get this fixed?
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Sparkplug90
Posted on Thursday, July 10, 2014 - 11:15 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes I did!! It was a bad connection, the plate that the regulator was bolted to that holds the battery in place was missing a spiked grounding washer. Found a spiked washer put it in, and she started right up!!
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Jfogal1986
Posted on Wednesday, April 08, 2015 - 04:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I am having a similar problem with my 1997 Thunderbolt S3. I have been having intermittent starting issues with the bike for a little while. A few months back, my ignition relay melted and I replaced it. Now, the bike sometimes has a hard time turning over. One day I went to start my bike - just a loud clicking/chatter as described above. I replaced the starter, and still have the noise. I replaced the voltage regulator - still just the noise. I believe based on my voltage tests that the stator is functional. Not sure if its related, but running light went out as well (not the bulb - bulb is functional in brake light spot, but running light port just won't work now). My voltage regulator is not near the battery. I only see one spiked grounding washer. Any ideas?
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Buell_bert
Posted on Thursday, April 09, 2015 - 06:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Batt. grd. to frame? Starter switch on the handle bar? Is the Battery in good condition?
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Jim2
Posted on Thursday, April 09, 2015 - 08:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I just posted on your other thread but just want to let you know that I didn't think it was my stator either. The A/C voltage tested good at 1000 rpm , 2000 rpm, and 3000 rpm, even though it was grounding out. I also replace a perfectly good starter when all this started.

Not sure what you mean by running-light. Can you clarify?
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Jfogal1986
Posted on Thursday, April 09, 2015 - 09:50 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

By running light I meant the taillight - there are two bulbs, one for brake and one thats a running light. Brake light works, bulb from running light works in brake light port, but nothing works in running light port. Also - high beam indicator light is out but high beam works.
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