Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual - page 9

TROUBLESHOOTING, Voltage Drop

procedure will help you

to locate poor connections or components with excessive
voltage drops.

Table 3-3. Starter Does Not Run or Runs at Very Low Speeds

SOLUTION

POSSIBLE CAUSE

SOURCE OF PROBLEM

Charge battery.

Voltage drop due to discharged battery.

Battery

Replace battery.

Short-circuit or open between electrodes.

Clean and retighten.

Poor contact condition of battery ter-
minal(s).

Repair or replace cable(s).

Poor or no connection at either end of the
battery positive or negative cable.

Wiring

Clean, tighten or replace cable(s) as
needed.

Cracked or corroded battery cable ends.

Tighten connections or repair or replace
wire(s).

Open wire(s) or poor connection at
handlebar switch or start relay, especially
relay ground wire (grounds through
TSM/TSSM/HFSM).

Replace switch.

Poor switch contacts or open switch.

Start switch, clutch switch, engine stop
switch or neutral switch

Replace relay.

Open coil winding.

Start relay

Replace relay.

Poor or no continuity at relay points.

Disarm security system inspect for neutral
or clutch circuit issue.

TSM/TSSM/HFSM has disabled start
relay.

Replace solenoid assembly.

Poor contact condition caused by burned
contacts.

Starter solenoid

Replace solenoid assembly.

Windings open or short-circuited.

Replace starter.

Brushes worn below specification.

Starter motor

Replace starter.

Commutator burnt.

Replace starter.

Commutator high mica.

Replace starter.

Field winding grounded.

Replace starter.

Armature winding grounded or short-cir-
cuited.

Replace starter.

Free running current draw out of range.

Replace starter.

Insufficient brush spring tension.

Replace starter clutch assembly.

Starter clutch failure.

Starter clutch

Table 3-4. Starter Spins But Does Not Engage

SOLUTION

POSSIBLE CAUSE

SOURCE OF PROBLEM

Charge battery.

Voltage drop due to discharged battery.

Battery

Replace battery.

Short-circuit or open between electrodes.

Clean and retighten.

Poor contact condition of battery ter-
minal(s).

Replace starter clutch assembly.

Pinion gear teeth worn out.

Starter motor

Replace clutch shell and sprocket.

Excessively worn teeth.

Gear teeth on clutch shell and sprocket.

Replace starter clutch assembly.

Starter clutch failure.

Starter clutch

3.2 STARTING SYSTEM, Starter Spins But Does Not
Engage

3-6 2011 Touring Diagnostics: Starting and Charging

Table 3-5. Starter Does Not Stop Running

SOLUTION

POSSIBLE CAUSE

SOURCE OF PROBLEM

Replace start switch or start relay.

Unopened contacts.

Start switch or start relay

Replace start switch or start relay.

Poor return caused by sticky switch or
relay contacts.

Replace starter solenoid assembly.

Coil shorted.

Starter solenoid

Replace starter solenoid assembly.

Contact plate melted and stuck.

STARTER TESTING

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

Table 3-6. Starter Testing Diagnostic Faults

POSSIBLE CAUSES

Short to voltage at starter solenoid

Start switch malfunction

Short to voltage on start relay supply circuit

Start relay malfunction

1. Starting System Operational Test

With IGN ON, transmission in neutral and the engine stop
switch in the RUN position, press the start switch.

Does the starter spin?

Yes. Starter spins, but does not engage. See

Yes. Starter stalls or spins too slowly. See

3.2 STARTING SYSTEM, Starter Stalls or Spins Too
Slowly

Yes. Starter runs on.

No.

SYSTEM, Starter Solenoid Clicks

2. Audible Noise Test

While listening for audible clicking noises from the start
relay and starter solenoid, press the start switch.

Is there a click?

Yes. Start solenoid clicks. See

3.2 STARTING

Yes. Start relay clicks. See

3.2 STARTING

SYSTEM, Start Relay Clicks

No. See

3.2 STARTING SYSTEM, Nothing Clicks

3. Starter Solenoid Test

Disconnect starter solenoid [128].

Does starter stop?

Yes.

No. Replace starter solenoid assembly. (5845)

4. Start Switch Circuit Test

Turn IGN OFF, remove start relay.

Turn IGN ON. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) test for voltage at fuse block
[64-1B] socket terminal 4H (BK/R) wire.

Is battery voltage present?

Yes.

No.

5. Start Switch Circuit Short to Voltage Test

Turn IGN OFF, disconnect right hand controls [22].

Turn IGN ON, test for voltage at [22B] terminal 6.

Is voltage present?

Yes. Except FLHR/C.

Yes. FLHR/C. Repair short to voltage between [22B]
terminal 6 and [64-1B] socket terminal 4H (BK/R) wire.

No.

6. Start Switch Circuit Short to Voltage [2B]
Test

Turn IGN OFF, disconnect interconnect harness [2].

Turn IGN ON, test for voltage at [2B] terminal 2.

Is voltage present?

Yes. Repair short to voltage between [2B] terminal 2
and [22B] terminal 6 (BK/R) wire. (5041)

No.

7. Start Switch Circuit Short to Voltage [2A]
Test

Test for voltage at [2A] terminal 2.

Is voltage present?

Yes. Repair short to voltage between [2A] terminal 2
and [64-1B] socket terminal 4H (BK/R) wire. (5041)

No.

8. Start Switch Test

Test for continuity between [22A] terminal 4 (W/BK) wire
and terminal 6 (BK/R) wire.

2011 Touring Diagnostics: Starting and Charging 3-7

Is continuity present?

Yes. Replace start switch. See the service manual.
(5818)

No. Repair short to voltage on [22A] terminal 6 (BK/R)
wire. (5041)

9. Start Relay Test

Perform relay test. See

TROUBLESHOOTING, Relay Diagnostics

Is the start relay good?

Yes. Perform wiggle test to locate short to voltage
between [64-1B] socket terminals 4G (GN) wire or
3H (R/GY) wire. See

TROUBLESHOOTING, Wiggle Test

. (5041)

No. Replace start relay. (5832)

NOTHING CLICKS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

BREAKOUT BOX

HD-42682

Table 3-7. Nothing Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Open fuse

Open ignition switch feed circuit

Start switch malfunction

Start relay malfunction

TSM/TSSM/HFSM malfunction

Ignition switch malfunction

Open ignition circuit

Open start switch circuit

Neutral switch malfunction

Open neutral circuit

Clutch switch malfunction

Open clutch switch circuit

Engine stop switch malfunction

Open ignition circuit

Open security circuit

NOTE

Verify that vehicle is in neutral and that the key fob is present
and in working order (if security equipped) and that the engine
stop switch is in RUN position.

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

No. Charge or replace battery as needed, attempt to
start engine, if nothing clicks continue with tests.

to Test 2.

2. Fuse Test

Verify that all fuses including main fuse are good.

Are all fuses good?

Yes.

No. Replace fuse and repair circuit accordingly. If
problem is still present, continue with tests.

Go to

Test 3.

3. Ignition Circuit Test

With IGN ON, verify that ignition circuit is working properly.

Do lights illuminate?

Yes.

No.

4. Ignition Switch Supply Voltage Test

With IGN OFF, disconnect ignition switch [33].

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and multimeter, test for battery voltage at ignition
switch [33B] terminal 2 on all vehicles except for FLHR/C
and terminal B on FLHR/C (R) wire.

Is battery voltage present?

Yes.

No. Except FLHR/C. Repair open between ignition
switch [33B] terminal 2 and main fuse [5B] terminal
B (R) wire. (5041)

No. FLHR/C.

5. Ignition Switch to [222] Test

Disconnect console ignition switch [222].

Test for continuity between ignition switch [33B] terminal
B and [222A] terminal B.

Is continuity present?

Yes. Repair open in (R) wire from [222B] terminal B
and [64-1B] socket terminal 2C.

No. Repair open in (R) wire from [222A] terminal B
and ignition switch [33B] terminals B.

6. Ignition Switch Test

With IGN ON, test for continuity between ignition switch
[33A] terminals B+ and IGN.

3-8 2011 Touring Diagnostics: Starting and Charging

Is continuity present?

Yes. On all vehicles except for FLHR/C, repair open
in (R/BK) wire from [33B] terminal 3. (5041)

No. Except FLHR/C. Replace ignition switch. See
the service manual. (7287)

No. FLHR/C.

7. Ignition Switch to [222] Continuity Test

Test for continuity between ignition switch [33B] terminal
A and [222A] terminal A.

Is continuity present?

Yes. Repair open in (R/BK) wire from [222B] terminal
B and [64-2B] socket terminal 1E.

No. Repair open in (R/BK) wire from [222A] terminal
B and ignition switch [33B] terminals B.

8. Start Switch Circuit Voltage Test

With IGN OFF, remove start relay.

Turn IGN ON.

While pressing the start switch, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-
meter, test for battery voltage at [64-1B] socket terminal
4H (BK/R) wire.

Is battery voltage present?

Yes.

Go to Test 11.

No.

Go to Test 9.

9. Start Switch Test

Turn IGN OFF and disconnect right hand controls [22].

With the start switch pressed, test for continuity between
[22A] terminals 6 (BK/R) wire and 4 (W/B) wire.

Is continuity present?

Yes.

Go to Test 10.

No. Replace the start switch. See the service manual.
(5818)

10. Start Switch Circuit Continuity Test

Test for continuity between [22B] terminal 6 and [64-1B]
socket terminal 4H (BK/R) wire.

Is continuity present?

Yes.

Go to Test 19.

No. Except FLHR/C.

Go to Test 11.

No. FLHR/C. Repair (BK/R) wire between [22B] ter-
minal 6 and [64-1B] socket terminal 4H.

11. Start Switch Circuit Continuity [2B] Test

Disconnect interconnect harness [2].

Test for continuity between [2B] terminal 2 and [22B] ter-
minal 6.

Is continuity present?

Yes. Repair open between [2B] terminal 2 and [22B]
terminal 6 (BK/R) wire. (5041)

No.

Go to Test 13.

12. Start Switch Circuit Continuity [2A] Test

Test for continuity between [2A] terminal 2 and [64-1B]
socket terminal 4H (BK/R) wire.

Is continuity present?

Yes.

No. Repair open between [2A] terminal 2 and [64-1B]
socket terminal 4H (BK/R) wire. (5041)

13. Start Relay Control Circuit Test

Test for continuity between [64-1B] socket terminal 3G
(TN/GN) wire and ground.

Is continuity present?

Yes. Replace start relay. See the service manual. If
problem is still present, see

3.2 STARTING SYSTEM,

Start Relay Clicks

. (5832)

No.

Go to Test 14.

14. Start Relay Control Circuit Open Test

Connect BREAKOUT BOX (Part No. HD-42682) between
wire harness [30B] and TSM/TSSM/HFSM [30A]. See

1.2 DIAGNOSTIC TOOLS

Test for continuity between [64-1B] socket terminal 3G
and breakout box terminal 9 (TN/GN) wire.

Is continuity present?

Yes.

Go to Test 15.

No, without anti-theft tracking module. Repair open
between [64-1B] socket terminal 3G and
TSM/TSSM/HFSM [30B] terminal 9 (TN/GN) wire.
(5041)

No, with anti-theft tracking module.

Go to Test 20.

15. TSM/TSSM/HFSM Ground Test

Test for continuity between breakout box terminal 12 (BK)
wire and ground.

Is continuity present?

Yes.

Go to Test 16.

No. Repair open between TSM/TSSM/HFSM [30B]
terminal 12 and right GND 2 (BK/GN) wire. (5041)

16. Continuity at Neutral Switch Test

Verify that transmission is in neutral.

Measure for resistance between breakout box terminal 4
(TN) wire and ground.

Is resistance less than 10 Ohms?

Yes.

Go to Test 18.

No.

Go to Test 17.

2011 Touring Diagnostics: Starting and Charging 3-9

17. Neutral Switch Ground Circuit Test

Test for continuity between neutral switch [131] (BK) wire
and ground.

Is continuity present?

Yes. Replace neutral switch. See the service manual.
(5157)

No. Repair open between neutral switch [131] and
GND 1 (BK) wire. (5041)

18. Start Relay Coil Control Circuit Short to
Voltage Test

Turn IGN ON.

Test for battery voltage on breakout box terminal 9.

Is battery voltage present?

Yes. Repair short to voltage between
TSM/TSSM/HFSM [30B] terminal 9 and [64-1B]
socket terminal 3G on (TN/GN) wire. (5041)

No. Replace TSM/TSSM/HFSM. See the service
manual. (5838)

19. Engine Stop Switch Voltage Test

Test for voltage between [22B] terminal 3 and ground.

Is battery voltage present?

Yes. Replace engine stop switch. See the service
manual.

No. Repair open between ignition fuse and [22B] (GY)
wire.

20. Relay Enable Circuit Continuity Test

Disconnect the anti-theft tracking module.

Test for continuity between [64-1B] socket terminal 3G
and anti-theft tracking module [266B] terminal C (TN/GN)
wire.

Is continuity present?

Yes.

Go to Test 21.

No. Repair open in (TN/GN) wire. (5041)

21. Anti-Theft Tracking Module Test

Test for continuity between breakout box terminal 9 and
anti-theft tracking module [266B] terminal D (TN/GN) wire.

Is continuity present?

Yes. Replace the anti-theft tracking module. See the
service manual. (6756)

No. Repair open in (GN) wire. (5041)

START RELAY CLICKS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

Table 3-8. Start Relay Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Starter solenoid malfunction

Open starter solenoid control circuit

Open starter solenoid ground circuit

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

No. Charge or replace battery as needed, attempt to
start engine, if start relay continues to click and starter
does not engage.

2. Starter Solenoid Control Coil Voltage Test

With IGN OFF, disconnect starter solenoid [128].

Turn IGN ON.

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for battery voltage on
[128B] terminal 1 (GN) wire.

Is battery voltage present when start switch is pressed?

Yes. Replace starter solenoid assembly. See the
service manual. (5845)

No.

3. Starter Solenoid Control Coil Continuity
Test

Turn IGN OFF and remove start relay.

Test for continuity between [128B] terminal 1 and fuse
block [64-1B] socket terminal 4G (GN) wire.

Is continuity present?

Yes. See

TROUBLESHOOTING, Relay Diagnostics

. If relay

tests good, continue with tests.

No. Repair open between [128B] terminal 1 and [64-
1B] socket terminal 4G (GN) wire. (5041)

4. Start Solenoid Wiring Inspection Test

Inspect for corrosion or damage to the wiring from [128A]
to starter solenoid.

Are there any problems?

Yes. Repair damage or replace starter solenoid
assembly. See the service manual. If problem is still
present, then continue with tests.

(5845)

No.

3.2 STARTING SYSTEM, Starter Solenoid

3-10 2011 Touring Diagnostics: Starting and Charging

5. Starter Solenoid Test

With IGN ON, press the start switch.

Does starter solenoid click?

Yes. See

Clicks

No. Repair open in [64-1B] socket terminal 3H (R/BK)
wire.

STARTER SOLENOID CLICKS

Table 3-9. Starter Solenoid Clicks Diagnostic Faults

POSSIBLE CAUSES

Low battery

Starter malfunction

Starter solenoid malfunction

Open battery cable

Open starter cable

Mechanical binding

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

No. Charge or replace battery as needed. Attempt to
start engine. If starter solenoid continues to click and
starter does not engage, then continue with tests.

to Test 2.

2. Starter Voltage Drop Test

Perform voltage drop tests from battery (+) to starter stud
on starter (BK) wire. See

TROUBLESHOOTING, Voltage Drop

Is voltage drop greater than 1.0V?

Yes.

No.

3. Starter Solenoid Voltage Drop Starter Side
Test

Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 2 (BK) wire.

Is voltage drop greater than 1.0V?

Yes.

No. Replace starter solenoid assembly. See the ser-
vice manual. (5845)

4. Starter Solenoid Battery Side Voltage
Drop Test

Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 1 (BK) wire.

Is voltage drop greater than 1.0V?

Yes. Repair or replace (BK) wire from starter solenoid
terminal 1 to battery (+) terminal. (5041)

No. Replace starter solenoid assembly. See the ser-
vice manual. (5845)

5. Starter Ground Circuit Voltage Drop Test

Perform voltage drop test from battery (-) terminal to
ground.

Is voltage drop greater than 1.0V?

Yes. Inspect (BK) wire for damage from battery (-)
terminal to chassis ground, repair or replace if
necessary.

No.

3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test

6. Starter Ground Test

Remove starter attaching bolts. See the service manual.

Clean bolts and starter base, install starter bolts.

Does engine crank?

Yes. Engine cranks at normal speed. Repair com-
plete.

Yes. Engine cranks, but at a slower speed. See

No. Replace starter. See the service manual. (5817)

7. Starter Draw Test

Perform Starter Current Draw Test on motorcycle. See

3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test

Perform Starter Motor Free Running Current Draw Test
(on bench). See

3.4 TESTING STARTER ON BENCH,

Free Running Current Draw Test

Are test results within range?

Yes.

No. Replace starter. See the service manual. (5817)

8. Mechanical Binding Test

Remove spark plugs and place transmission in 5th gear.

Raise vehicle.

Rotate rear wheel.

Check for engine binding in the primary and/or crankshaft
or starter clutch.

Is engine binding? See the service manual.

Yes. Repair as needed. (Use appropriate code).

No. Replace starter solenoid assembly. (5845)

2011 Touring Diagnostics: Starting and Charging 3-11

STARTER SPINS BUT DOES NOT ENGAGE

Table 3-10. Starter Spins But Does Not Engage Diagnostic

Faults

POSSIBLE CAUSES

Clutch assembly

Clutch shell and sprocket

1. Pinion Gear and Clutch Shell Test

Remove primary cover.

Inspect for damage to starter pinion gear and clutch shell
and sprocket.

Is damage present?

Yes. Replace the clutch assembly or clutch shell and
sprocket. See the service manual. (5825)

No. Replace the clutch assembly. See the service
manual. (5837)

STARTER STALLS OR SPINS TOO SLOWLY

Table 3-11. Starter Stalls or Spins Too Slowly Diagnostic

Faults

POSSIBLE CAUSES

Low battery

Starter malfunction

Starter solenoid malfunction

Poor connections at starter ground

Open battery cable

Open starter cable

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

AND TROUBLESHOOTING, Voltage Drop

No. Charge or replace battery as needed. If symptom
is still present, then continue with tests.

Go to Test

2. Starter Stud Voltage Drop Test

Perform voltage drop test from battery (+) terminal to
starter stud on starter (BK) wire. See

1.3 DIAGNOSTICS

Is voltage drop greater than 1.0V?

Yes.

No.

3. Starter Ground Circuit Voltage Drop Test

Perform voltage drop test between battery (-) terminal and
starter attaching bolts.

Is voltage drop greater than 1.0V?

Yes. Clean ground connections. (5041)

No.

3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test

4. Starter Draw Test

Perform Starter Current Draw Test on motorcycle. See

Perform Starter Motor Free Running Current Draw Test
(on bench). See

3.4 TESTING STARTER ON BENCH,

Free Running Current Draw Test

Are test results within range?

Yes. With the spark plugs removed and the transmis-
sion in 5th gear, rotate rear wheel. Check for engine,
primary and/or crankshaft bind. (Use appropriate
code)

No. Replace starter. See the service manual. (5817)

5. Starter Solenoid Voltage Drop Starter Side
Test

Perform voltage drop test between battery (+) terminal to
starter solenoid terminal 2.

Is voltage drop greater than 1.0V?

Yes.

No. Repair connection or (BK) wire between starter
solenoid and starter. (5041)

6. Starter Solenoid Battery Side Voltage
Drop Test

Perform voltage drop test between battery (+) terminal
and starter solenoid terminal 1 (R) wire.

Is voltage drop greater than 1.0V?

Yes. Repair or replace connection between battery
(+) terminal and starter solenoid terminal 1 (R) wire.
(5041)

No. Repair or replace starter solenoid assembly. See
the service manual. (5845)

3.4 TESTING STARTER ON BENCH, Free Running
Current Draw Test

3-12 2011 Touring Diagnostics: Starting and Charging

3.3

TESTING STARTER ON MOTORCYCLE

STARTER CURRENT DRAW TEST

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

NOTES

•

Engine temperature should be stable and at room temper-
ature.

•

Battery should be fully charged.

Check starter current draw with an induction ammeter before
disconnecting battery. Proceed as follows:

Verify that transmission is in neutral and engine stop switch
is in OFF position.

Remove start relay.

Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), connect patch cord to fuse block [64-1B] socket
terminals 4G and 3H.

Clamp induction ammeter over positive starter cable to
starter solenoid.

NOTE

In next step with engine stop switch in OFF position and purple
male probes connected to the [64-1B] terminals 4G and 3H in
place of the start relay, starter will turn but engine will not start.
This configuration also prevents diagnostic trouble codes from
being set.

With IGN ON, read the ammeter. Disregard initial high
current reading which is normal when engine is first turned
over.

Typical starter current draw will range between 160-
200A.

If starter current draw exceeds 250A, then the
problem may be in the starter or starter drive. See

2011 Touring Diagnostics: Starting and Charging 3-13

3.4

TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST

Place starter in vise, using a clean shop towel to prevent
scratches or other damage.

Figure 3-5

. Attach one heavy jumper cable (6 gauge

minimum).

Connect one end to the starter mounting flange.

Connect the other end to the battery (-) terminal of a
fully charged battery.

Connect a second heavy jumper cable (6 gauge minimum).

Connect one end to the battery (+) terminal of the
battery.

Connect the other end to the battery terminal on the
starter. Place an induction ammeter over cable.

Keep fingers and clothing away from starter gear to pre-
vent personal injury. (00613b)

Connect a smaller jumper cable (14 gauge minimum).

Connect one end to the positive (+) terminal of the
battery.

Connect the other end to the solenoid relay terminal.

Check ammeter reading.

Ammeter should show 90A max.

If reading is higher, replace starter. See the service
manual.

If starter current draw on vehicle was over 120A and
this test was within specification, there may be a
problem with engine or primary drive.

ed02865

Mounting flange

Battery

Induction ammeter

Battery terminal

Relay terminal

Figure 3-5. Free Running Current Draw Test

STARTER SOLENOID

Do not disassemble solenoid. Before testing, disconnect field
wire from solenoid motor terminal as shown in

Figure 3-6

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 per-
formed together in one continuous operation. Conduct all three
tests one after the other in the sequence given without interrup-
tion.

SOLENOID PULL-IN TEST

ON BENCH, Solenoid Pull-In Test

Figure 3-6

. Using a 12V battery, connect three sep-

arate test leads as follows:

Solenoid housing to negative battery post.

Solenoid motor terminal to negative battery post.

Solenoid relay terminal to positive battery post.

Observe starter shaft.

If starter shaft extends strongly, solenoid is working
properly.

If starter shaft does not extend strongly, replace
solenoid assembly.

ed02866

Battery

Solenoid housing

Solenoid relay terminal

Solenoid motor terminal

Figure 3-6. Pull-In Test

SOLENOID HOLD-IN TEST

See

Figure 3-7

. With test leads still connected in the

manner specified in the previous

3.4 TESTING STARTER

, disconnect solenoid

motor terminal/battery negative test lead at negative bat-
tery post only; reconnect loose end of this test lead to
positive battery post instead.

3-14 2011 Touring Diagnostics: Starting and Charging

Observe starter shaft.

If starter shaft remains extended, solenoid is working
properly.

If starter shaft retracts, replace solenoid assembly.

ed02867

Battery

Solenoid housing

Solenoid relay terminal

Solenoid motor terminal

Figure 3-7. Hold-In Test

SOLENOID RETURN TEST

manner specified at the end of

Figure 3-8

. With test leads still connected in the

3.4 TESTING STARTER

ON BENCH, Solenoid Hold-In Test

, disconnect solenoid

relay terminal/positive battery post test lead at either end.

Observe starter pinion.

If starter shaft retracts, solenoid is working properly.

If starter shaft does not retract, replace solenoid
assembly.

ed02868

Battery

Solenoid housing

Solenoid relay terminal

Solenoid motor terminal

Figure 3-8. Return Test

2011 Touring Diagnostics: Starting and Charging 3-15

3.5

CHARGING SYSTEM

DESCRIPTION AND OPERATION

The charging system is the source of electric current that sup-
plies power to run the ignition, lights, accessories and charge
the battery. AC voltage is generated by an alternator assembly
driven by the crankshaft. A rotor supplied with a magnetic field
spins around a stator. A rectifier (located in the regulator)
converts the voltage from AC to DC. A regulator ensures that
the output voltage is properly matched to the battery voltage
as engine speed varies. Even though the alternator provides
additional voltage at all engine speeds, it is not recommended
to idle the vehicle for long periods of time.

Alternator

The alternator consists of two main components:

•

The rotor which mounts to the primary side of the crank-
shaft.

•

The stator which is attached to the crankcase half.

Voltage Regulator

Figure 3-9

. The voltage regulator is a series regulator.

The circuit combines the functions of rectifying and regulating.

TROUBLESHOOTING

When the charging system fails to charge or does not charge
at a satisfactory rate, check the following items.

Battery

Test for a weak or dead battery. Battery must be fully charged
in order to perform a load test or starting or charging tests. See

Wiring

The stator connections must be clean and tight.

Check for corroded or loose connections in the charging system
circuit.

Voltage Regulator Inspection

The voltage regulator must have clean, tight connections for
proper operation. Verify both AC and DC connectors are fully
inserted and locked with the regulator latch.

Job/Time Code Values

Dealership Technicians filing warranty claims should use the
job/time code values printed in bold text next to the appropriate
repair.

Connector Information

For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see

B.1 CONNECTORS

Stator

Main Fuse

40A

Starter

Battery

Red
Band

Battery

Ground

Left

GND1
(Dirty)

BK
BK
BK

[77A]

[77B]

[47B]

[47A]

[5B]

em00692

Figure 3-9. Charging System Circuit

3-16 2011 Touring Diagnostics: Starting and Charging

LOW OR NO CHARGING

Table 3-12. Low or No Charging Diagnostic Faults

POSSIBLE CAUSES

Low battery

Stator malfunction

Rotor malfunction

Voltage regulator malfunction

Open voltage regulator circuit

Stator shorted to ground

AC wire shorted to ground

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

No. Charge or replace battery as needed. Verify
repair.

NOTE

A discharged battery may show a reading under 13V even
though the charging system is working properly.

2. Off Idle Voltage Test

With the vehicle is neutral, start engine and run at 3000
rpm.

Test battery voltage.

Is voltage above 13V?

Yes. Charging system working properly.

No.

3. AC Output Test

Perform an AC output test. See

3.5 CHARGING SYSTEM,

Battery Charging Tests

Did the output test pass?

Yes.

No.

4. Stator Test

Perform a stator test. See

3.5 CHARGING SYSTEM,

Battery Charging Tests

Is the stator good?

Yes.

No. Replace stator. See the service manual. (5309)

5. Rotor Inspection Test

Inspect the rotor for damage.

Remove center bolt and inspect for signs of the center
hole becoming oval. See the service manual.

Verify that stator bolts have not backed out and contacted
the rotor.

Is rotor in good condition?

Yes.

No. Replace rotor. See the service manual. (5319)

6. Voltage Regulator Power Circuit Test

With IGN OFF, disconnect voltage regulator [77].

Test for continuity between voltage regulator [77B] terminal
+ and main fuse [5B].

Is continuity present?

Yes.

No. Repair open wire between voltage regulator [77B]
terminal + and [5B]. (5041)

7. Voltage Regulator Ground Circuit Test

NOTE

The voltage regulator ground must have a clean, tight connec-
tion for proper grounding.

Test for continuity between voltage regulator [77B] terminal
- and ground.

Is continuity present?

Yes. Replace voltage regulator. See the service
manual. (5316)

No. Repair open wire between voltage regulator [77B]
terminal - and GND 1 (BK) wire. (5041)

OVERCHARGING

Table 3-13. Overcharging Diagnostic Faults

POSSIBLE CAUSES

Voltage regulator malfunction

1. Battery Voltage Test

With the vehicle in neutral, start engine and run at 3000
rpm, test battery voltage.

Is voltage above 15.5V?

Yes.

No. Charging system working properly.

2. Voltage Regulator Ground Circuit Test

NOTE

The voltage regulator ground must have a clean, tight connec-
tion for proper grounding.

With IGN OFF, disconnect voltage regulator [77].

Test for continuity between voltage regulator [77B] terminal
- and ground.

2011 Touring Diagnostics: Starting and Charging 3-17

Is continuity present?

Yes. Replace voltage regulator. See the service
manual. (5316)

No. Repair open wire between voltage regulator [77B]
terminal - and GND 1 (BK) wire. (5041)

LOW BATTERY AFTER EXTENDED IGN OFF

Table 3-14. Low Battery After Extended IGN OFF

Diagnostic Faults

POSSIBLE CAUSES

Battery

Accessories improperly wired to stay on at all times

Excessive draw from electrical component with IGN OFF

Battery self-discharge and/or component draw because
motorcycle was not operated for a long period

1. Battery Test

Verify battery condition. See

Is battery condition good?

Yes.

SYSTEM, Battery Charging Tests

No. Charge or replace battery as needed. Verify
repair.

2. Amp Draw Test

Perform a milliampere draw test. See

3.5 CHARGING

Did the test exceed maximum draw?

Yes. Repair excessive draw and run test again. (5308)

No. System is working properly.

BATTERY RUNS DOWN DURING USE

Table 3-15. Battery Runs Down During Use Diagnostic

Faults

POSSIBLE CAUSES

Low battery

Excessive accessory draw

Accessories on when idling or low rpm riding for extended
period

1. Total Current Draw Test

Perform a Total Current Draw and Output Test. See

3.5 CHARGING SYSTEM, Battery Charging Tests

Does charging system exceed current draw by 3.5A?

Yes.

No. System accessory power requirements exceed
charging system capability.

2. Battery Test

Verify battery condition. See

Is battery condition good?

Yes. System is working properly.

No. Charge or replace battery as needed.

BATTERY CHARGING TESTS

TOOL NAME

PART NUMBER

HARNESS CONNECTOR TEST KIT

HD-41404-C

Milliampere Draw Test

NOTE

Be sure accessories are not wired so they stay on at all times.
This condition could drain battery completely if vehicle is parked
for a long time. Test for this by connecting ammeter between
negative battery terminal and battery.

If vehicle is equipped with HFSM, enable service mode
before performing test.

Disconnect the security siren (if equipped).

Remove main fuse.

NOTE

With IGN OFF, an initial current draw of up to 200 mA will occur
directly after connecting meter. This should drop to the values
shown in

Table 3-16

in less than one minute.

Figure 3-10

. Using HARNESS CONNECTOR TEST

KIT (Part No. HD-41404-C), connect ammeter to main
fuse socket terminals. With this arrangement, you will pick
up any drain.

With IGN OFF and all lights and accessories off, observe
current reading.

Add voltage regulator draw to appropriate value for
TSM/TSSM/HFSM and ECM. If observed ammeter
reading is less than listed in table, draw is within limits.
Refer to

Table 3-16

A higher reading indicates excessive current draw.
Any accessories must be considered and checked
for excessive drain.

3-18 2011 Touring Diagnostics: Starting and Charging

Table 3-16. Milliampere Draw Test

MAXIMUM DRAW

IN MILLIAMPERES

ITEM

1.0

ECM

1.0

Speedometer

1.0

Tachometer

1.0

TSM (no security)

3.0

TSSM (armed)

3.0

TSSM (disarmed)

1.0

TSSM (storage mode)

1.0

HFSM

20.0*

Security siren (optional)

2.0

Voltage regulator

2.0

Radio

1.0

High output amplifier

1.0

CB module

1.0

XM module

* Siren draws for 2-24 hours from the time the motorcycle
battery is connected and 0.05 milliamperes once siren battery
is charged. Disconnect siren during milliampere draw test.

Left

GND1
(Dirty)

Stator

1 2 3

- +

[5B]

[77A]

[77B]

[47B]

[47A]

em00693

Ammeter

Main fuse socket

Voltage regulator

Figure 3-10. Milliampere Draw Test (Ignition Turned to

OFF)

Total Current Draw and Output Test

If battery runs down during use, the current draw of the
motorcycle components and accessories may exceed output
of the charging system.

NOTE

If a load tester is unavailable, an ammeter with current probe
may be used.

Turn battery load tester OFF before connecting tester
cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
which could result in death or serious injury. (00252a)

See

Figure 3-11

. Connect load tester.

Connect negative and positive leads to battery ter-
minals.

Place load tester induction pickup over battery neg-
ative cable.

With IGN OFF, disconnect voltage regulator [77].

Start engine.

Turn all continuously running lights and accessories turned
ON (headlamp on high beam).

Run engine at 3000 rpm, and make note of the current
draw.

Turn engine OFF.

With IGN OFF, connect voltage regulator [77].

Remove the induction pickup from the battery negative
cable.

Place induction pickup over positive regulator cable.

10. Start engine and run at 3000 rpm.

NOTE

Do not leave any load switch turned on for more than 20
seconds or overheating and tester damage are possible.

11. Increase the load as required to obtain a constant 13.0V.

12. Current output should be 35-50A. Make note of current

output.

NOTE

Rider's habits may require output test at lower rpm.

13. Compare both of these readings.

The current output should exceed current draw by
3.5A minimum.

If output does not meet specifications, there may be
too many accessories for the charging system to
handle.

2011 Touring Diagnostics: Starting and Charging 3-19

ed02802

Load tester

Induction pickup

Battery

Figure 3-11. Check Current Draw (Ignition Switch On)

Stator Test

Turn IGN OFF.

Figure 3-12

. Connect an ohmmeter.

Disconnect voltage regulator [47] from stator wiring.

Insert one ohmmeter lead into a stator connector
socket.

Attach the other lead to a suitable ground.

Test for continuity.

A good stator will show no continuity (open circuit)
between all stator sockets and ground.

Any other reading indicates a grounded stator which
must be replaced.

See

Figure 3-13

. Remove ground lead. Measure resist-

ance across stator [47B] terminals 1-2, 2-3 and 3-1.

Resistance across all the stator terminals should be
0.1-0.3 Ohm.

If the resistance is higher, the stator is damaged and
must be replaced.

If resistance is lower, the stator may have a turn-to-
turn short and should be replaced.

NOTE

When measuring resistance (Ohms), compensate for test lead
resistance before performing the measurement. Select the
Ohms position and touch the test leads together. Refer to the
multimeter user's manual to either zero the display or manually
subtract the test lead resistance from the measured circuit's
value.

ed02027

Figure 3-12. Test for Grounded Stator (Typical)

ed02028

Figure 3-13. Check for Stator Resistance (Typical)