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Harley Davidson Sportster Models 2009. Service Repair Manual - page 43

1.6

TESTING STARTER ON BENCH

FREE RUNNING CURRENT DRAW TEST

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

See

Figure 1-7

. Attach one heavy jumper cable (6 gauge

minimum).

Connect one end to the starter mounting flange.

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

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

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

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

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 90 amps maximum.

If reading is higher, disassemble starter for inspection.
See the service manual.

If starter current draw on vehicle was over 200 amps,
and this test was within specification, there may be a
problem with engine or primary drive.

ed02794

Mounting flange

Battery

Induction ammeter

Battery terminal

Relay terminal

Figure 1-7. Free Running Current Draw Test

STARTER SOLENOID

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

Figure 1-8

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

See

Figure 1-8

. Using a 12 volt battery, connect three

separate 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 the
solenoid.

ed02795

Motor terminal

Relay terminal

Battery

Figure 1-8. Pull-In Test

SOLENOID HOLD-IN TEST

See

Figure 1-9

. With test leads still connected in the

manner specified in the previous

1.6 TESTING STARTER

ON BENCH, Solenoid Pull-In Test

, 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.

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2009 Sportster Diagnostics: Starting / Charging 1-15

Observe starter shaft.

If starter shaft remains extended, solenoid is working
properly.

If starter shaft retracts, replace the solenoid.

ed02796

Motor terminal

Relay terminal

Battery

Figure 1-9. Hold-In Test

SOLENOID RETURN TEST

See

Figure 1-10

. With test leads still connected in the

manner specified at the end of the previous

1.6 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 the solenoid.

ed02797

Motor terminal

Relay terminal

Battery

Figure 1-10. Return Test

TESTING

Armature

Remove armature and brush holder from field coil. See
the service manual.

Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.015 in.
(0.38 mm) of runout should be replaced or machined on
a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (29.98 mm).

Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.20 mm), use an undercutting machine to
undercut the mica to 1/32 in. (0.79 mm) deep. The slots
should then be cleaned to remove any dirt or copper dust.

NOTES

•

See

Figure 1-11

. If an undercutting machine is not avail-

able, undercutting can be done satisfactorily using a thin
hacksaw blade. After undercutting, lightly sand the arma-
ture with crocus cloth to remove any burrs.

•

Do not use sandpaper or emery cloth on commutator. The
abrasive grit may remain on commutator segments and
could cause excessive brush wear.

See

Figure 1-12

. Check for a SHORTED ARMATURE.

Place armature on growler.

Hold a thin steel strip (hacksaw blade), against the
armature core and slowly turn armature.

A shorted armature will cause the steel strip to vibrate
and be attracted to the core. Replace the armature if
shorted.

See

Figure 1-13

. Check for a GROUNDED ARMATURE

with an ohmmeter or continuity tester.

Touch one probe to any commutator segment.

Touch the other probe to the armature core.

There should be no continuity (infinite ohms). If there
is continuity, the armature is grounded. Replace a
grounded armature.

See

Figure 1-14

. Check for an OPEN ARMATURE with

an ohmmeter or continuity tester.

Check for continuity between all commutator seg-
ments.

There should be continuity (0 ohms) at all test points.
If there is no continuity at any test point, then the
armature is open. Replace an open armature.

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1-16 2009 Sportster Diagnostics: Starting / Charging

sm02320

Segments

Mica

Incorrect (Mica must not be left with a thin edge next to segments)

Correct (Mica must be cut away clean between segments)

Starting groove in mica with 3 cornered file

Undercutting mica with piece of hacksaw blade

Commutator

Figure 1-11. Undercutting Mica Separators

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2009 Sportster Diagnostics: Starting / Charging 1-17

sm02325

Growler

Thin steel strip (hacksaw blade)

Figure 1-12. Shorted Armature Test Using Growler

sm03710

Figure 1-13. Grounded Armature Test

sm03711

Figure 1-14. Armature Open Test

Brushes and Brush Holder

Remove armature and brush holder from field coil. See
the service manual.

Measure the brush length. If any one of four brushes is
less than 0.433 in. (11 mm), replace the field coil and brush
holder assembly. No further testing is necessary.

See

Figure 1-15

. Check for a GROUNDED FIELD COIL

WINDING with an ohmmeter or continuity tester.

Touch one probe to the field coil housing (frame).

Touch the other probe to each of two brushes
attached to the field coil winding.

There should be no continuity (infinite ohms). If there
is continuity at either brush, then the field coil winding
is grounded. Replace the field coil/brush holder
assembly if grounded.

See

Figure 1-16

. Check for an OPEN FIELD COIL

WINDING with an ohmmeter or continuity tester.

Touch one probe to the field wire.

Touch the other probe to each of the two brushes
attached to the field coil winding(s).

There should be continuity (0 ohms). If there is no
continuity at either brush, then the field coil winding(s)
are open. Replace the field coil/brush holder assembly
if open.

See

Figure 1-17

. Test the BRUSH HOLDER INSULATION

with an ohmmeter or continuity tester.

Touch one probe to the holder plate.

Touch the other probe to each of the positive (insu-
lated) brush holders.

There should be no continuity (infinite ohms). If there
is continuity at either brush holder, replace the field
coil/brush holder assembly.

Touch one probe to the non-insulated brush holders
and the other probe to the holder plate. If any resist-
ance is measured, replace the field coil/brush holder
assembly.

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Figure 1-15. Grounded Field Test

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1-18 2009 Sportster Diagnostics: Starting / Charging

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Figure 1-16. Open Field Test

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Figure 1-17. Brush Holder Insulation Test

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2009 Sportster Diagnostics: Starting / Charging 1-19

1.7

CHARGING SYSTEM

GENERAL

The charging system consists of the alternator and regulator.
The charging system circuit is shown in

Figure 1-20

Alternator

The alternator consists of two main components:

•

The rotor which mounts to the engine sprocket shaft.

•

The stator which bolts to the engine crankcase.

Voltage Regulator

See

Figure 1-18

. The voltage regulator (1) is a series regulator

with shunt control. The circuit combines the functions of recti-
fying and regulating.

ed02798

Voltage regulator

DC output connector [77]

Figure 1-18. Voltage Regulator (Typical)

TROUBLESHOOTING

TOOL NAME

PART NUMBER

ELECTRICAL SYSTEM TESTER

HD-48053

When the charging system fails to charge or does not charge
at a satisfactory rate, make the following recommended checks.

Battery

Check for a weak or dead battery. See

1.8 BATTERY TESTING

for battery testing procedures. Battery must be fully charged
in order to perform a load test, or starting or charging tests.
However, a partially discharged battery may be tested using
the BATTERY TEST function of the ELECTRICAL SYSTEM
TESTER (Part No. HD-48053).

Wiring

See

Figure 1-19

. The stator connector plug and socket connec-

tion must be clean and tight.

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

Figure 1-20

ed02799

Figure 1-19. Stator Connector [46] (typical)

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1-20 2009 Sportster Diagnostics: Starting / Charging

BK BK

30 Amp

Main Fuse

Powertrain

Ground

Point

Stator

Voltage

Regulator

Battery

GND1

–

[5]

[46B]

[46A]

[77A]

[77B]

em00279

Figure 1-20. Charging System Circuit

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2009 Sportster Diagnostics: Starting / Charging 1-21

Charging System Test (Part 1 of 2)

Test battery.

Charge or replace as required.

Inspect regulator for loss connections.

PASS

FAIL

Perform MILLIAMP DRAW

TEST (If applicable).

Correct as

required.

5306

PASS

Perform TOTAL CURRENT

DRAW TEST.

Record measurement.

FAIL

Isolate

damaged

component or

wiring.

5308

PASS

FAIL

Isolate damaged

wiring or

excessive

accessories.

5310

NOTE

Whenever a charging system component fails a test and
is replaced, re-test the system to be sure the problem
has been corrected.

fc01948_en

Replace

grounded

stator.

Disconnect regulator.

Does milliamp draw

drop?

YES

5312

Go to Charging

System Test (Part

2 of 2).

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1-22 2009 Sportster Diagnostics: Starting / Charging

Charging System Test (Part 2 of 2)

Continued From Charging System Test (Part 1 of 2).

Perform CURRENT AND VOLTAGE OUTPUT TEST. Record measurement and

compare with TOTAL CURRENT DRAW TEST before proceeding.

PASS

FAIL

Perform

VOLTAGE

OUTPUT TEST.

Perform

STATOR CHECK.

PASS

FAIL

Replace

voltage regulator.

System tests good up to this point.

Suspect:

• Accessories on for long periods when
vehicle is parked and not running.

• Accessories on when vehicle is
ridden very slowly for long periods.

• Battery self-discharge and/or
accessory draw because vehicle was
not operated for a long period.

5316

PASS

FAIL

Perform AC

OUTPUT TEST.

Replace

stator.

5312

PASS

Replace voltage

regulator.

Perform CURRENT

OUTPUT TEST.

Inspect rotor.

FAIL

PASS

Damaged or

slipping rotor.

System

OK.

5315

NOTE

Whenever a charging system component fails a test and
is replaced, re-test the system to be sure the problem
has been corrected.

5319

FAIL

PASS

Replace

stator.

Replace

rotor.

5314

5319

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2009 Sportster Diagnostics: Starting / Charging 1-23

TESTING

TOOL NAME

PART NUMBER

ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM
ANALYZER

HD-48053

Milliampere Draw Test

NOTES

•

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. Check for this by con-
necting ammeter between negative battery cable and
ground.

•

TSM/TSSM/HFSM will continue to draw 16-25 mA for 30
seconds after ignition is turned off. Any disruption and
reconnection of battery power, such as disconnecting the
battery to place a meter in series, will cause TSM/TSSM/
HFSM to draw 16-25 mA for 30 seconds.

See

Figure 1-21

. Connect ammeter between negative

battery cable and crankcase ground. With this arrange-
ment, you will also pick up any regulator drain.

With ignition switch turned to OFF and all lights and
accessories off, observe current reading.

Refer to

Table 1-4

. Add voltage regulator draw to

appropriate value for TSM/TSSM/HFSM. If sum is
greater than reading observed on ammeter, draw is
within limits.

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

NOTE

A battery with a surface discharge condition could suffer a
static drain. Correct by cleaning battery case.

Table 1-4. Maximum Meter Reading (Averaged)

DRAW IN MILLIAMPERES

ITEM

Voltage regulator

Speedometer

Tachometer (if equipped)

TSM (non-security models)

TSSM (disarmed)

TSSM (armed)

TSSM (storage mode)

HFSM

20.0*

Security siren

* Siren will draw for 2-24 hours from time motorcycle battery
is connected and 0.05 milliamperes once siren battery is
charged. For best results, disconnect siren during milliampere
draw test.

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12 VDC battery

Battery negative cable

Crankcase

Figure 1-21. Milliampere Draw Test (Ignition turned to OFF)

Total Current Draw 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 1-22

. To check for this condition, place load

tester induction pickup or current probe pickup over battery
negative cable.

Disconnect stator plug from voltage regulator. Start the
motorcycle and run the engine at 2000 RPM.

With ignition and all continuously running lights and
accessories turned on (headlamp on high beam), read the
total current draw.

Compare this reading to the reading obtained after per-
forming the CURRENT AND VOLTAGE OUTPUT TEST.

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

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

Reconnect voltage regulator after testing.

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1-24 2009 Sportster Diagnostics: Starting / Charging

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Load tester

Induction pickup

Battery

Figure 1-22. Check Current Draw (Ignition Switch On)

Current and Voltage Output Test: Using
HD-48053

Connect the ADVANCED BATTERY CONDUCTANCE
AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-
48053) leads to the vehicle's battery.

Follow the instructions in the analyzer's instruction manual
to perform a Charging System Test.

See

Figure 1-23

. The test results will include a decision on the

charging system's condition and the measured output voltage
at idle and at 3000 RPM. The analyzer's printer will provide
you with a printout including one of two possible test results:

•

CHARGING SYSTEM NORMAL - No problem found.

•

CHARGING SYSTEM PROBLEM - The analyzer detected
a problem and will display one of the three following res-
ults:

LOW CHARGING VOLTS - The alternator is not supplying
sufficient current for the system's electrical loads.

HIGH CHARGING VOLTS - The voltage output from the
alternator exceeds the normal regulator limits.

INVESTIGATE VOLT OUTPUT - The rev voltage is lower
than the idle voltage.

ed02804

Figure 1-23. Charging System Test Results Printout

Current and Voltage Output Test: Using
Load Tester

See

Figure 1-24

. Connect load tester.

Connect negative and positive leads to battery ter-
minals.

Place load tester induction pickup over positive regu-
lator cable.

Run the engine at 3000 RPM. Increase the load as
required to obtain a constant 13.0 VDC. Do not leave any
load switch turned on for more than 20 seconds or over-
heating and tester damage can occur.

The current output should be 24-30 amps. Make 0note of
measurement for use in Total Current Draw Test.

NOTE

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

See

Figure 1-24

. After removing the load, read the load

tester voltage meter.

If voltage to the battery is not more than 15 VDC,
voltage output is within specifications. Investigate
other possible problems.

If voltage is higher, voltage regulator is not functioning
properly or connections are loose or dirty.

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2009 Sportster Diagnostics: Starting / Charging 1-25

ed02803

Load tester

Battery

Voltage regulator

To MAXIFUSE (DC output)

To stator

Figure 1-24. Current and Voltage Output Test

Stator Check

Turn ignition switch OFF.

Connect an ohmmeter.

Open latch and separate socket connector from pin
connector.

See

Figure 1-25

. Insert one ohmmeter lead into a

stator connector (1) socket.

Attach the other lead to a suitable ground (4).

Test for continuity with ohmmeter set to the ohms scale
(2).

A good stator will show no continuity between either
stator socket and ground.

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

See

Figure 1-26

. Remove ground lead. Check resistance

across stator sockets.

Test for resistance with ohmmeter set on the RX1 scale.

Resistance across the stator sockets should be 0.1-
0.3 ohms.

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

NOTE

Verify that meter reads 0 ohms when probes are shorted
together. If not, subtract lowest value from resistance value of
stator.

ed02805

Alternator stator connector [46B]

DVOM set to ohms scale

Positive meter lead to either stator connector
socket

Negative meter lead grounded to engine

Figure 1-25. Test for Grounded Stator (Typical)

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1-26 2009 Sportster Diagnostics: Starting / Charging

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Alternator stator connector [46B]

DVOM set to ohms scale

Meter leads to stator connector sockets

Figure 1-26. Check for Stator Resistance (Typical)

AC Output Check

See

Figure 1-27

. Test AC output.

Disconnect voltage regulator connector from alternator
stator wiring.

Connect an AC voltmeter across both stator connector
sockets.

Run the engine at 2000 RPM. The AC output should
be 40-56 volts AC (approximately 20-28 volts AC per
1000 RPM).

Compare test results to specifications.

If the output is below specifications, charging problem
could be a faulty rotor or stator.

If output is good, charging problem might be faulty
voltage regulator. Replace as required.

Check the output again as previously described under
CURRENT AND VOLTAGE OUTPUT TEST.

ed02810

Alternator stator connector [46B]

DVOM set to AC volts scale

Meter leads to stator connector sockets

Figure 1-27. Check Stator AC Voltage Output (Typical)

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2009 Sportster Diagnostics: Starting / Charging 1-27

1.8

BATTERY TESTING

GENERAL

Three different procedures may be performed to provide a
good indicator of battery condition: a voltage test, a conduct-
ance test, or a load test.

A battery may be tested, whether fully charged or not, via
conductance test. In order to perform a load test, however, the
battery must be fully charged.

VOLTMETER TEST

The voltmeter test provides a general indicator of battery state
of charge or condition. Check the voltage of the battery to verify
that it is in a 100% fully charged condition. Refer to

Table 1-5

If the open circuit (disconnected) voltage reading is below
12.6V, charge the battery and then recheck the voltage after
the battery has set for one to two hours. If the voltage reading
is 12.7V or above, perform the Load Test described in this
section.

Table 1-5. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGE

VOLTAGE

100%

12.7

75%

12.6

50%

12.3

25%

12.0

11.8

CONDUCTANCE TEST

TOOL NAME

PART NUMBER

ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM
ANALYZER

HD-48053

Test the battery using the ADVANCED BATTERY CONDUCT-
ANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-
48053). Perform a battery test as follows:

Connect the HD-48053 analyzer leads to the vehicle bat-
tery lead terminal, not to bolt or wire terminal.

NOTE

Connect the tester directly to the lead terminals of the battery,
and not the bolts.

Follow the instructions in the analyzer instruction manual
to perform a battery test.

The test results will include a decision on the battery condition
and the measured state of charge.

See

Figure 1-28

. The analyzer printer will provide you with a

printout including one of six possible test results:

•

GOOD BATTERY - Return the battery to service.

•

GOOD-RECHARGE - Fully charge the battery and return
to service.

•

CHARGE & RETEST - Fully charge the battery and retest.

•

REPLACE BATTERY - Replace the battery and retest.

•

BAD CELL-REPLACE - Replace the battery and retest.

•

BATTERY NOISE - Remove surface charge from battery
and retest.

NOTES

•

A REPLACE BATTERY test result may also mean a poor
connection between the battery cables and the vehicle.
After disconnecting the battery cables from the battery,
retest the battery using the out-of-vehicle test before
replacing.

•

Connect the tester directly to the lead terminals of the
battery, and not the bolts.

ed02811

Figure 1-28. Battery Test Results Printout

LOAD TEST

To load test the battery, proceed as follows:

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

Remove battery from motorcycle.

Always fully charge the battery before testing or test
readings will be incorrect. Load testing a discharged bat-
tery can also result in permanent battery damage.

After charging, allow battery to stand for at least one hour
before testing.

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1-28 2009 Sportster Diagnostics: Starting / Charging

See

Figure 1-29

. Connect tester leads to battery posts

and place induction pickup over negative (black) cable.

NOTE

To avoid load tester and/or battery damage, do not leave the
load tester switch turned ON for more than 20 seconds.

Refer to

Table 1-6

. Load battery at 50% of CCA rating

using the load tester. Voltage reading after 15 seconds
should be 9.6V or more at 70° F (21° C).

Turn battery load tester OFF before disconnecting tester
cables to battery terminals. Disconnecting tester cables
with load tester ON can cause a spark and battery explo-
sion, which could result in death or serious injury. (00253a)

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter-
minal bolts could result in damage to battery terminals.
(00216a)

Install the battery in the motorcycle.

ed02876

Load tester

Induction pickup

Battery

Figure 1-29. Load Test Battery

Table 1-6. Battery Load Test

50%

100%

COLD CRANKING

AMPERAGE (CCA)

102.5

205

Sportster models

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2009 Sportster Diagnostics: Starting / Charging 1-29

1-30 2009 Sportster Diagnostics: Starting / Charging

NOTES

Content .. 41 42 43 44 ..