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Dfbutler
Posted on Sunday, January 15, 2012 - 02:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I've been experiencing a run of odd, intermittant problems on my 99 S3. The last few days the starter has been going click instead of cranking. A couple of tries has resulted in cranking and starting, but yesterday I gave up and tried to bump start unsuccessfully and then as a last ditch I tried the starter and it started. Does not happen every time and there is no apparent pattern. Solenoid? Starter? something else?
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Thylacine
Posted on Sunday, January 15, 2012 - 02:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Battery voltage? Loose cables?
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Dfbutler
Posted on Sunday, January 15, 2012 - 02:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Don't think so, I've got an HID headlight and it goes off if the voltage drops too low.
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Hootowl
Posted on Sunday, January 15, 2012 - 03:04 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Check the contacts on your solenoid. I believe you'll find that one side contact as well an the ring contact are eroded. Cheap enough to replace.

Disconnect the battery. Remove the three screws on the solenoid cover (on the starter) and pull out the plunger. You'll see the contacts on the sides, and the ring contact on the plunger. These are wear items.
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Maxbuell
Posted on Sunday, January 15, 2012 - 03:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Starter relay? not sure if S3 have but my 02 M2 does and caused the same promblem.
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Harleyelf
Posted on Sunday, January 15, 2012 - 03:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes, my '99 S3 has a starter relay. I had a similar problem last year. Replaced both relays, replaced all fuses, scraped diodes and battery cables clean and re-installed, and then I finally replaced the ignition switch. That fixed it.
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Sportyeric
Posted on Sunday, January 15, 2012 - 06:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The starter relay is available at any auto shop for ten bucks. I'd start there.
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Dfbutler
Posted on Sunday, January 15, 2012 - 08:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have to tell you, this forum is amazing. Ask a question and you've got an answer in a couple of hours.
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Buellistic
Posted on Sunday, January 15, 2012 - 08:51 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Dfbutler:

Be sure to tell us what you found wrong ???
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Jim2
Posted on Sunday, January 15, 2012 - 11:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The replacement relays I bought for my 00 M2 are:
Duralast Part#19389

Got them at Autozone.

probably same for most or all tubers.

I had the same symptoms as you described.

(Message edited by jim2 on January 15, 2012)
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Dfbutler
Posted on Monday, January 16, 2012 - 10:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hootowl, Where do you get those parts? Can you change them with the starter still on the bike? Is the in the FSM?
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Harleyelf
Posted on Monday, January 16, 2012 - 11:20 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I see seven pages of how to test and repair the motor and one half page on how to remove and re-install the solenoid plunger. Not a word about repairing solenoids. If you polish anything in there use crocus cloth instead of emery or carbide paper so you don't leave debris.
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Hootowl
Posted on Monday, January 16, 2012 - 11:22 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes you can change them with the starter still installed, but it's tricky. You need a very short wrench and a lot of patience. I've done it to mine, and a few other's bikes with it still installed, so it is definitely doable.

You can get solenoid rebuild kits from HD dealers, just tell them it is for a Sportster. You can find them online too, and for much cheaper. I've posted links a few times...I'll see if I can find them.
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Hootowl
Posted on Monday, January 16, 2012 - 11:26 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Here you go...

http://www.badweatherbikers.com/buell/messages/476 23/583070.html#POST1878949

http://www.liquidchopperstore.com/m17756.html

Under $12



This kit doesn't contain the spring, but you can reuse your old one as long as you disconnect your battery first. See thread above. : )
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Hootowl
Posted on Monday, January 16, 2012 - 11:28 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sorry, no, it isn't in the manual, at least, not my manual. Stupid simple to replace though, just time consuming.
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Hootowl
Posted on Monday, January 16, 2012 - 04:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bit of a warning about the kit above: It says it fits sportster, but I'm being told that this may not be the case, as the number doesn't appear to cross. The contacts sure look like XL contacts to me though.

I've never installed this kit (got mine from a HD dealer) so buyer beware.

Hopefully Al will start carrying rebuild kits soon, and then we'll know we're getting the right parts.
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Coxster
Posted on Monday, January 16, 2012 - 11:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you can get a meter on it, check the "S" terminal ( the smallest one on the starter ) for 10-14V. If you're not seeing any voltage there, look upstream at a relay. If you do see voltage at the S terminal, then check the "M" (Motor) terminal opposite side of the battery cable on the opposite side of the 'Doghouse' as I call it. If you don't see it here the contacts inside are tired. These starters have several similar parts to what is on a few million Toyotas out there, and any old rebuild shop should be able to sell you the contacts and a new plunger too. ( I worked for the Case/New Holland Reman program as a product engineer a few years back - all Denso starters are identical inside, just different sizes ) PM me if you need more help
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Koz5150
Posted on Tuesday, January 17, 2012 - 09:43 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I had a similar issue for almost 2 years until I found corrosion between the swingarm ground strap and the frame. I cleaned up the connection by the frame and replaced the washer with a stainless one. problem solved.
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Fahren
Posted on Tuesday, January 17, 2012 - 10:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Another great resource thread! One problem with just about every possible diagnostic and solution posted up by the collective knowledge of a bunch of old school Buell owners.

Unfortunately, as Buellistic and others have stated before, it will eventually end up buried in the archives, where a search may or may not turn it up for future reference.
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Coxster
Posted on Tuesday, January 17, 2012 - 11:24 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Koz5150 = Genius! I would have never thought of that. I got my '54 Ford going once by putting a 12 ga wire from a starter bolt to the firewall, so what you say makes perfect sense.
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Dfbutler
Posted on Tuesday, January 17, 2012 - 04:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Great suggestion. Is there any simple way to check the ground continuity?
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Harleyelf
Posted on Tuesday, January 17, 2012 - 05:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ohm meter between frame & battery ground and also between swing arm & battery ground. Should read zero.
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S1owner
Posted on Tuesday, January 17, 2012 - 06:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I had the same issue on my 96 S1 this past summer i ended up starting at the run switch and going through every point of contact for the ignition. It ended up being the contacts at the starter i cleaned them and resecured them and the issue is solved i also have an ignition issue but that is being replaced
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Koz5150
Posted on Wednesday, January 18, 2012 - 12:34 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I am no genius, it took me 2 years to figure this out on my bike. I found it in a quiet garage and followed the smoke...
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Alphabuell
Posted on Monday, March 24, 2014 - 12:02 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The search function worked for me it was like digging up an old treasure. Fixed my clicking start today! 2 years later and its still alive!
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