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Harley Davidson 2008 Touring Models. Electrical Diagnostics Manual - page 2

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em01117

Battery

BN/GY

Ignition

Serial data link

LGN/V

Neutral switch

TSM/

TSSM/

HFSM

Start relay control

TN/GN

Clutch switch

BK/R

Ground

BK/GN

Red

Band

[30A] [30B]

Battery

Electronic

Control

[78A]

[78B]

Module (ECM)

Starting System

40A

MAXIFUSE

Serial data link

LGN/V

[5B]

[

128A]

[128B]

Engine stop switch

W/BK

Starter

Right Hand

Controls

IGNITION SWITCH LEGEND

“X” INDICATES CONTINUITY

BETWEEN LEAD WIRES

SWITCH

IN POSITION INDICATED

POSITION

RED/

RED

GRAY

BLACK

Engine Stop Switch

LOCK

OFF

Starter Switch

IGN

BK/GN

ACC

(Black)

[1A] [1B]

Ignition

(Black)

Switch

[22A]

[22B]

Rear

Front

GND2

GND1

(Clean)

(Dirty)

[33B]

W/BK

R/GY

BK/R

R/BK

[64-2B]

(Gray)

Ignition - 15A

[2A] [2B]

R/BK

BK/GN

[64-1B]

BK/R

Battery - 15A

BN/GY

To ignition

relay

BK/R

R/GY

Start

BK/R

Relay

TN/GN

(Gray)

[24A]

[24B]

BK/R

Front GND

To instrument fuse

Stud

(Dirty)

BK/GN

Clutch

Switch

[GND1A]

[21A]

16-way on all except FLHTP

[21B]

12-way on FLHTP

[131]

(BK)

Neutral

Left Hand

Switch

Neutral

Controls

Figure 1-2. Starting Circuit (FLHX, FLHT/C/U, FLTR)

2008 Touring Diagnostics: Starting / Charging 1-5

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Starter Testing 1

Check Battery using visual inspection,

Voltage Test, and either Conductance Test or

Load Test.

Check connections at Battery and Starter

components.

Is system operational?

YES

Starter

Spins, But

Stalls or

Check for audible

Starter Runs On.

Does Not

Spins Too

clicking noise.

Engage.

Slowly.

Disconnect solenoid relay terminal

from Solenoid.

See Starter Testing 5: Starter

See Starter Testing 6: Starter

Solenoid clicks. See Starter

Is 12V present on (GN) wire with

Spins, But Does Not Engage.

Stalls or Spins Too Slowly.

Testing 2: Solenoid Clicks.

Starter Button not pressed?

YES

Is 12V present on connector [64-1]

start relay socket terminal “86” with

starter button not pressed?

Replace

Relay clicks. See

NOTE:

Start Solenoid.

Starter Testing 3: Relay Clicks.

Depending on relay used relay

socket terminal could be shown as

5845

“1” or “4H”.

YES

Nothing clicks. See Starter Testing

4: Nothing Clicks (Part 1 of 2).

Replace

Starter Button.

Start Relay.

5818

5832

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1-6 2008 Touring Diagnostics: Starting / Charging

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Starter Testing 2: Solenoid Clicks

Perform voltage drop test between battery

negative and relay terminal on Solenoid.

Is voltage drop less than 1.0 volt?

YES

Perform voltage drop test from

Pinpoint poor connections or

battery positive to starter motor

relay contact problems using

terminal. Crank Engine.

voltage drop test.

Voltage greater than 1.0 volt?

5823

YES

Perform voltage drop test

Perform voltage drop test from

between battery negative and

battery positive to starter battery

starter studs or bolts.

terminal. Crank Engine.

Is voltage drop greater than 1.0

Is voltage drop greater than 1.0 volt?

volt?

YES

Repair connection

Repair or replace

Clean ground

Does Starter Motor

between Battery and

Solenoid (contacts).

connections.

turn if jumped?

Starter.

5845

5824

YES

Replace

Replace or repair

Solenoid.

Starter Motor.

5860

5817

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2008 Touring Diagnostics: Starting / Charging 1-7

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Starter Testing 3: Relay Clicks

Test for voltage at starter solenoid

terminal connector [128B] (GN).

Is 12V present when Starter Button is

pressed?

YES

Does Starter Motor

Test for voltage to Start Relay.

turn if jumped?

Is 12V present on connector

[64-1] relay socket terminal “30”?

NOTE:

Depending on relay used relay

socket terminal could be shown

YES

as “3” or “3H”.

5827

Replace Starter

Replace or repair

Solenoid.

Starter Motor.

5860

5817

YES

Repair open on (R/BK)

Test for voltage from Start Relay.

wire feeding connector [64-1]

Is 12V present on connector [64-1] relay socket

relay socket terminal “30”.

terminal “87” when Starter Button is pressed?

NOTE:

Depending on relay used

Depending on relay used relay socket terminal

relay socket terminal could

could be shown as “5” or “4G”.

be shown as “3” or “3H”.

YES

Repair open on (GN)

Replace

wire between Start Relay

Start Relay.

and Starter Solenoid.

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5827

5832

1-8 2008 Touring Diagnostics: Starting / Charging

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Starter Testing 4: Nothing Clicks (Part 1 of 2)

Do turn signals work properly?

YES

Is TSM/TSSM/HFSM connector

Turn the Ignition Switch to

[30] fully mated?

IGNITION. With the Engine Stop

Switch in the RUN position,

depress the start switch while

checking for battery voltage at

YES

start relay terminal “86”.

Is battery voltage present?

Continuity to ground on TSM/

Mate connector [30].

NOTE:

TSSM/HFSM terminal “12”?

Depending on relay used relay

6792

socket terminal could be shown

as “1” or “4H”.

YES

Continuity on TSM/TSSM/HFSM

Repair open.

terminal “1” to battery fuse?

6805

YES

Continuity on TSM/TSSM/HFSM

Repair open.

terminal “2” to IGN fuse?

6806

YES

Replace TSM/TSSM/HFSM. Learn

Repair open.

password and perform set-up.

6791

6793

YES

Check for continuity to chassis ground at start relay terminal “85”.

Disconnect connector [22]. Check for continuity

Is continuity present?

between terminal “4” (W/BK) and terminal “6”

NOTE:

(BK/R) of connector [22A].

Depending on relay used relay socket terminal could be shown as

Continuity present with start switch pressed?

“2” or “3G”.

YES

Check for continuity from start relay

Turn the Ignition Switch to IGNITION.

terminal “85” to terminal “9” on TSM/

Check for voltage to start switch, at

Replace

TSSM/HFSM connector [30].

connector [22B] terminal “3” (GY).

start switch.

Substitute good

Is continuity present?

Battery voltage present?

5818

relay or test relay.

NOTE:

Depending on relay used relay

socket terminal could be shown as

“2” or “3G”.

YES

Locate and repair

YES

open in (BK/R) wire

open in (GY) wire

from connector [22B]

Repair open.

to start relay.

to IGN fuse.

5831

STOP

5828

Go to Starter Testing 4:

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Nothing Clicks (Part 2 of 2).

2008 Touring Diagnostics: Starting / Charging 1-9

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Starter Testing 4: Nothing Clicks (Part 2 of 2)

Continued from

Starter Testing 4: Nothing Clicks (Part 1 of 2).

Install breakout box HD-42682. Shift transmission to neutral. Measure continuity

to chassis ground at breakout box terminal “4” (Gray) (neutral switch).

Is continuity (less than 10 ohms) present?

YES

Disengage clutch (pull in clutch lever). Measure

Disconnect neutral switch connector [131]. Check

continuity to chassis ground at breakout box terminal

for continuity between breakout box terminal “4”

“10” (Gray) (clutch switch) with clutch disengaged.

(Gray) and connector [131] terminal “B” (TN).

Is continuity present?

YES

Check for continuity from

Locate and repair open on

connector [131] terminal “A”

(TN) wire between neutral

(BK) to chassis ground.

switch and TSM/TSSM/

Is continuity present?

HFSM.

5862

YES

Replace Neutral

Locate and repair open on

Switch.

(BK) wire between neutral

5157

switch and ground.

YES

Turn Ignition Switch to IGNITION. Check for

Disconnect left hand controls connector [24]. Check

voltage on breakout box terminal “9” (Gray).

for continuity between breakout box terminal “10”

Is voltage present?

(Gray) and connector [24B] terminal “7” (BK/R).

Is continuity present?

YES

Locate and repair

Replace TSM/TSSM/HFSM.

short to voltage on

Learn password and

Check for continuity from

Locate and repair open on

(TN/GN).

perform set-up.

connector [24B] terminal “8”

(BK/R) wire between clutch

5830

5838

(BK/GN) to chassis ground.

switch and TSM/TSSM/

Is continuity present?

HFSM.

YES

Replace Clutch

Locate and repair open on

Switch.

(BK/GN) wire between clutch

switch and ground.

5168

5861

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1-10 2008 Touring Diagnostics: Starting / Charging

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Starter Testing 5: Starter Spins, But Does Not Engage

Remove Starter. Disassemble Drive Housing

Assembly. Inspect for damage to Armature

Gear or Idler Gear.

Damage present?

YES

Replace damaged Idler

Starter Clutch failure.

Gear and Armature.

Replace Starter Clutch.

5825

5837

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2008 Touring Diagnostics: Starting / Charging 1-11

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Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop test from battery positive to

starter motor terminal. Crank Engine.

Voltage greater than 1.0 volt?

YES

Perform voltage drop test

between battery positive to

between battery negative and

starter battery terminal.

starter studs or bolts.

Is voltage drop greater than 1.0

Crank Engine.

Is voltage drop greater than 1.0

volt?

YES

Perform starter motor current

Repair connection

draw test (on vehicle).

Repair or replace

between Battery and

Solenoid (contacts).

Clean Ground

Starter.

Perform starter motor free running

connections.

current draw bench test.

5824

5845

5835

Are test results within range?

YES

Remove Spark Plugs. While in

5th gear, rotate rear wheel.

Replace or repair

Check for Engine, Primary

Starter Motor.

and/or Crankshaft bind.

5817

Use appropriate code

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1-12 2008 Touring Diagnostics: Starting / Charging

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DIAGNOSTICS/TROUBLESHOOTING

1.3

until the source of the potential difference is found. The

VOLTAGE DROP

benefits of doing it this way are speed and accuracy.

Check the integrity of all wiring, switches, fuses and connectors

a. Readings are not as sensitive to real battery voltage.

between the source and destination.

b. Readings show the actual voltage dropped, not just

The voltage drop test measures the difference in potential or

the presence of voltage.

the actual voltage dropped between the source and destination.

c. This tests the system as it is actually being used. It

1. See ITEM A in Figure 1-3. Attach your red meter lead to

is more accurate and will display hard to find poor

the most positive part of the circuit, which in this case

connections.

would be the positive post of the battery (5).

d. This approach can be used on lighting circuits, ignition

2. See ITEM B in Figure 1-3. Attach the black meter lead to

circuits, etc. Start from most positive and go to most

the final destination or component in the circuit (solenoid

negative (the destination or component).

terminal from relay).

3. Activate the starter and observe the meter reading. The

See ITEM D in Figure 1-3. The negative or ground circuit

meter will read the voltage dropped or the difference in

can be checked as well.

potential between the source and destination. An ideal

a. Place the negative lead on the most negative part of

circuit's voltage drop would be

0 volt or no voltage

the circuit (or the negative battery post). Remember,

dropped, meaning no difference in potential.

there is nothing more negative than the negative post

of the battery.

4. See ITEM C in Figure 1-3. An open circuit should read 12

volts, displaying all the voltage dropped, and the entire

b. Place the positive lead to the ground you wish to

difference in potential displayed on the meter.

check.

NOTE

c. Activate the circuit. This will allow you to read the

Open circuits on the ground side will read zero.

potential difference or voltage dropped on the neg-

ative or ground circuit. This technique is very effective

5. Typically, a good circuit will drop less than 1.0 volt. If the

for identifying poor grounds due to powdered paint.

voltage drop is greater, back track through the connections

Even the slightest connection may cause an ohm-

meter to give a good reading. However, when suffi-

cient current is passed through, the resistance caused

by the powdered paint will cause a voltage drop or

potential difference in the ground circuit.

2008 Touring Diagnostics: Starting / Charging 1-13

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STARTER ACTIVATION CIRCUITS

1.4

STARTER ACTIVATION CIRCUITS

ed02788

ITEM A

ITEM B

0.1A

IDEAL CLOSED

CIRCUIT

20A

VDC

200A

ITEM C

ITEM D

0.1A

OPEN CIRCUIT

0.1A

GROUND CIRCUIT

20A

VDC

12V

20A

VDC

200A

1. Start switch

2. Relay

3. Solenoid

4. Starter

5. Battery

6. MAXIFUSE

7. Ignition switch

8. Ignition fuse

Figure 1-3. Typical Circuitry. Refer to wiring diagrams for more information.

1-14 2008 Touring Diagnostics: Starting / Charging

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TESTING STARTER ON MOTORCYCLE

1.5

START RELAY TEST

STARTER CURRENT DRAW TEST

1. See Figure 1-4. Locate the start relay behind the left side

NOTES

cover.

•

Engine temperature should be stable and at room temper-

2. See Figure 1-5. The start relay can be tested using the

ature.

motorcycle's 12 volt battery and a multimeter.

•

Battery should be fully charged.

a. Unplug connector from relay.

See Figure 1-6. Check starter current draw with an induction

b. To energize relay, connect the "85"(2) and relay ter-

ammeter before disconnecting battery. Proceed as follows:

minal "86"(1) to the positive battery terminal.

1. Verify that transmission is in neutral. Disconnect spark

c. Check for continuity between the 30 (3) and 87 (5)

plug wires from spark plug terminals.

terminals. A good relay shows continuity (continuity

2. Clamp induction ammeter over positive battery cable next

tester lamp "on" or a zero ohm reading on the ohm-

to starter.

meter). A malfunctioning relay will not show continuity

and must be replaced.

3. With ignition switch to IGNITION, turn engine over by

pressing starter switch while reading the ammeter. Dis-

3. If start relay is functioning properly, proceed to

regard initial high current reading which is normal when

1.5 TESTING STARTER ON MOTORCYCLE, Starter

engine is first turned over.

Current Draw Test.

a. Typical starter current draw will range between 160

to 200 amperes.

ed01343

b. If starter current draw exceeds 250 amperes, then

64-1B

the problem may be in the starter or starter drive.

15A

Remove starter for further tests. See 1.6 TESTING

15A

STARTER ON BENCH, Free Running Current Draw

Test.

15A

NOTE

A DC current probe may be used if an induction ammeter is

64-2B

15A

not available.

15A

ed02864

30A

15A

30A

Figure 1-4. Start Relay

ed01000

(3)

(2)

(1)

(5)

1. Starter

2. Induction Ammeter

1. Ohmmeter

3. Battery

2. Battery

3. Start relay

Figure 1-6. Starter Current Draw Test

Figure 1-5. Start Relay Test

2008 Touring Diagnostics: Starting / Charging 1-15

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TESTING STARTER ON BENCH

1.6

FREE RUNNING CURRENT DRAW TEST

STARTER SOLENOID

Place starter in vise, using a clean shop towel to prevent

Do not disassemble solenoid. Before testing, disconnect field

scratches or other damage.

wire from motor terminal as shown in Figure 1-8.

See Figure 1-7. Attach one heavy jumper cable (6 gauge

Each test should be performed for only 3-5 seconds to prevent

minimum).

damage to solenoid.

a. Connect one end to the starter mounting flange (1).

The solenoid Pull-in, Hold-in, and Return tests must be per-

formed together in one continuous operation. Conduct all three

b. Connect the other end to the negative (-) terminal of

tests one after the other in the sequence given without interrup-

a fully charged battery (2).

tion.

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

SOLENOID PULL-IN TEST

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

1. See Figure 1-8. Using a 12 volt battery, connect three

battery (2).

separate test leads as follows:

b. Connect the other end to the battery terminal (4) on

a. Solenoid housing to negative battery post.

the starter solenoid. Place an inductive ammeter (3)

over cable.

b. Solenoid motor terminal to negative battery post.

c. Solenoid relay terminal to positive battery post.

Connect a smaller jumper cable (14 gauge minimum).

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

2. Observe starter shaft.

battery (2).

a. If starter shaft extends strongly, solenoid is working

b. Connect the other end to the solenoid relay terminal

properly.

(5).

b. If starter shaft does not extend strongly, replace the

solenoid.

Check ammeter reading.

a. Ammeter should show 90 amps maximum.

b. If reading is higher, disassemble starter for inspection.

ed00204

See the Service Manual.

c. 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.

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1. Motor terminal

2. Relay terminal

3. Battery

Figure 1-8. Pull-In Test

SOLENOID HOLD-IN TEST

1. Mounting flange

1. See Figure 1-9. With test leads still connected in the

2. Battery

manner specified in the previous 1.6 TESTING STARTER

3. Induction ammeter

ON BENCH, Solenoid Pull-In Test, disconnect solenoid

4. Battery terminal

motor terminal/battery negative test lead at negative bat-

5. Relay terminal

tery post only; reconnect loose end of this test lead to

Figure 1-7. Free Running Current Draw Test

positive battery post instead.

1-16 2008 Touring Diagnostics: Starting / Charging

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2. Observe starter shaft.

STARTER ON BENCH, Solenoid Hold-In Test, disconnect

solenoid relay terminal/positive battery post test lead at

a. If starter shaft remains extended, solenoid is working

either end.

properly.

2. Observe starter pinion.

b. If starter shaft retracts, replace the solenoid.

a. If starter shaft retracts, solenoid is working properly.

b. If starter shaft does not retract, replace the solenoid.

ed00205

ed00206

1. Motor terminal

2. Relay terminal

3. Battery

1. Motor terminal

Figure 1-9. Hold-In Test

2. Relay terminal

3. Battery

Figure 1-10. Return Test

SOLENOID RETURN TEST

1. See Figure 1-10. With test leads still connected in the

manner specified at the end of the previous 1.6 TESTING

2008 Touring Diagnostics: Starting / Charging 1-17

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CHARGING SYSTEM

1.7

GENERAL

TROUBLESHOOTING

The charging system consists of the alternator and voltage

PART NUMBER

TOOL NAME

regulator. Charging system circuits are shown in Figure 1-12.

HD-48053

ADVANCED BATTERY CONDUCT-

Alternator

ANCE AND ELECTRICAL SYSTEM

ANALYZER

The alternator consists of two main components:

When the charging system fails to charge or does not charge

•

The rotor which mounts to the engine sprocket shaft.

at a satisfactory rate, make the following recommended checks.

•

The stator which bolts to the engine crankcase.

Battery

Voltage Regulator

Check for a weak or dead battery. See 1.8 BATTERY TESTING

See Figure 1-11. The voltage regulator is a series regulator.

for battery testing procedures. Battery must be fully charged

The circuit combines the functions of rectifying and regulating.

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 ADVANCED BATTERY

ed02026

CONDUCTANCE AND ELECTRICAL SYSTEM ANA-

LYZER (Part No. HD-48053).

Wiring

The stator and battery plug and socket connections must be

clean and tight.

See Figure 1-12. Check for corroded or loose connections in

the charging circuit.

Voltage Regulator Inspection

The voltage regulator must have a clean, tight connection for

proper operation. Check by using an ohmmeter with one lead

on chassis ground, such as battery ground cable, and the other

on the voltage regulator ground lead.

1. Stator (AC) Connector [47A]

2. Voltage Regulator (DC) Connector [77A]

Job/Time Code Values

Figure 1-11. Voltage Regulator (Bottom View) AC and DC

Dealership technicians filing warranty claims should use the

Connectors

job/time code values printed in bold text underneath the

appropriate repair.

1-18 2008 Touring Diagnostics: Starting / Charging

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em00176

Stator

[77B] [77A]

[47A] [47B]

40 A

MAXIFUSE

B A

Red

Front

Band

Dirty GND

Powertrain

Battery

Starter

Grounds

Figure 1-12. Charging System Circuit (Typical)

2008 Touring Diagnostics: Starting / Charging 1-19

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Charging System Test (Part 1 of 2)

Test Battery.

Charge or replace as required.

Inspect Voltage Regulator.

See Voltage Regulator Inspection.

PASS

FAIL

Perform MILLIAMPERE DRAW

Correct as

TEST.

required.

5306

Disconnect Regulator.

FAIL

Does milliamp draw drop?

PASS

YES

Perform TOTAL CURRENT

Replace grounded

Isolate damaged

DRAW TEST.

Stator.

component or wiring.

Record measurement.

5312

5308

PASS

FAIL

Isolate damaged wiring or

STOP

excessive accessories.

5310

Go to Charging

System (Part 2 of 2).

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1-20 2008 Touring Diagnostics: Starting / Charging

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Charging System Test (Part 2 of 2)

From Charging System (Part 1 of 2).

Perform CURRENT and VOLTAGE OUTPUT TEST.

Record measurement and compare with TOTAL CURRENT

DRAW TEST before proceeding.

PASS

FAIL

Perform

Is voltage less than 15.0V?

STATOR CHECK.

YES

PASS

FAIL

System tests good up to this point. Suspect:

Perform

Replace

Accessories on for long periods when vehicle is

AC OUTPUT CHECK.

Stator.

parked and not running.

5312

Replace Voltage

Accessories on when vehicle is ridden very slowly

Regulator.

for long periods.

PASS

FAIL

5316

Battery self-discharge and/or accessory draw

because vehicle was not operated for a long

Replace Voltage Regulator.

period.

Perform CURRENT and

Inspect Rotor.

VOLTAGE OUTPUT TEST.

NOTE:

Whenever a charging system component fails a test and

5315

is replaced, retest the system to be sure the problem has

been corrected.

PASS

FAIL

PASS

FAIL

Replace

System OK.

Damaged Rotor.

Replace Stator.

Rotor.

5319

5314

5319

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2008 Touring Diagnostics: Starting / Charging 1-21

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TESTING

ed02989

PART NUMBER

TOOL NAME

HD-41404-B

HARNESS CONNECTOR TEST KIT

2 3

HD-48053

ADVANCED BATTERY CONDUCT-

[47A]

ANCE AND ELECTRICAL SYSTEM

ANALYZER

Milliampere Draw Test

[77A]

[77B]

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-

[5B]

necting ammeter between negative battery terminal and

battery.

•

TSM/TSSM/HFSM will continue to draw 16-25 mA for 30

seconds after ignition is turned OFF. Any disruption and

[GND2]

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.

Disconnect siren during milliamperes draw test. (Siren may

1. Ammeter

draw up to 20 mA.)

2. MAXIFUSE socket

1. Remove left side cover. Remove MAXIFUSE.

3. Voltage regulator

2. See Figure 1-13. Using HARNESS CONNECTOR TEST

Figure 1-13. Milliampere Draw Test (Ignition Turned to

KIT (Part No. HD-41404-B) red male socket probes and

OFF)

patch cords, connect ammeter to MAXIFUSE socket ter-

minals. With this arrangement, you will also pick up any

regulator drain.

Table 1-4. Milliampere Draw Test

3. With ignition switch turned to OFF and all lights and

accessories off, observe current reading.

ITEM

MAXIMUM DRAW

IN MILLIAMPERES

a. Refer to Table 1-4. Add regulator draw ammeter

reading to appropriate value for TSM/TSSM/HFSM/

ECM

1.0

ECM. If observed ammeter reading is less than listed

Speedometer

1.0

in table, draw is within limits.

achometer

1.0

b. A higher reading indicates excessive current draw.

TSM (no security)

1.0

Any accessories must be considered and checked

for excessive drain.

TSSM (armed)

3.0

TSSM (disarmed)

3.0

NOTE

TSSM (storage mode)

1.0

A battery with a surface discharge condition could suffer a

static drain. Correct by cleaning battery case.

HFSM

1.0

Security Siren (optional)

20.0*

Voltage Regulator

2.0

Radio

2.0

High Output Amplifier

1.0

CB Module

1.0

XM Module

1.0

* Siren will draw for 2-24 hours from time motorcycle battery

is connected and 0.05 milliamperes once siren battery is

charged. Disconnect siren during milliampere draw test.

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.

1-22 2008 Touring Diagnostics: Starting / Charging

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NOTE

Follow the instructions in the analyzer's instruction manual to

perform a Charging System Test.

If a load tester is unavailable, an ammeter with current probe

may be used.

See Figure 1-15. The test results will include a decision on the

charging system's condition and the measured system voltage

at idle and at 3000 RPM. The analyzer's printer will provide

you with a printout including one of two possible test results:

Turn battery load tester OFF before connecting tester

1. CHARGING SYSTEM NORMAL - No problem found.

cables to battery terminals. Connecting tester cables with

load tester ON can cause a spark and battery explosion,

2. CHARGING SYSTEM PROBLEM - The analyzer detected

which could result in death or serious injury. (00252a)

a problem and will display one of the three following res-

ults:

1. See Figure 1-14. To check for this condition, place load

tester induction pickup or current probe pickup over battery

a. LOW CHARGING VOLTS - The alternator is not

negative cable.

supplying sufficient current for the system's electrical

loads.

2. Disconnect stator plug from voltage regulator. Start the

motorcycle and run the engine at 2000 RPM.

b. HIGH CHARGING VOLTS - The voltage output from

the alternator exceeds the normal regulator limits.

3. With ignition and all continuously running lights and

accessories turned on (headlamp on high beam), read the

c. INVESTIGATE VOLT OUTPUT - The rev voltage is

total current draw.

lower than the idle voltage.

4. Compare this reading to the reading obtained after per-

Current and Voltage Output Test: Using

forming the CURRENT AND VOLTAGE OUTPUT TEST.

Load Tester

a. The current output should exceed current draw by

3.5 amps minimum.

1. See Figure 1-14. Connect load tester.

a. Connect negative and positive leads to battery ter-

b. If output does not meet specifications, there may be

minals.

too many accessories for the charging system to

handle.

b. Place load tester induction pickup over positive regu-

lator cable.

5. Reconnect voltage regulator after testing.

2. Run the engine at 3000 RPM. Increase the load as

required to obtain a constant 13.0VDC. Do not leave any

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load switch turned on for more than 20 seconds or over-

heating and tester damage are possible.

3. The current output should be 35-50 amps. Make note of

measurement for use in TOTAL CURRENT DRAW TEST.

NOTE

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

4. See Figure 1-14. After removing the load, read the load

tester voltage meter.

a. If voltage to the battery is not more than 15V, voltage

output is within specifications. Investigate other pos-

sible problems. See Charging System Test.

b. If voltage is higher, voltage regulator is not functioning

properly.

Figure 1-14. Check Durrent Draw (Ignition Switch On)

Current and Voltage Output Test: Using

HD-48053

Connect ADVANCED BATTERY CONDUCTANCE AND

ELECTRICAL SYSTEM ANALYZER (Part No. HD-48053) to

the vehicle's battery.

2008 Touring Diagnostics: Starting / Charging 1-23

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Figure 1-15. Charging System Test Results Printout

Stator Check

1. Turn ignition switch OFF.

2. See Figure 1-16. Connect an ohmmeter.

a. Disconnect voltage regulator connector from alternator

Figure 1-16. Test for Grounded Stator (Typical)

stator wiring.

b. Insert one ohmmeter lead into a stator connector

socket.

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c. Attach the other lead to a suitable ground.

3. Test for continuity with ohmmeter set to the ohms scale.

a. A good stator will show no continuity (open circuit)

between any stator sockets and ground.

b. Any other reading indicates a grounded stator which

must be replaced.

4. See Figure 1-17. Remove ground lead. Check resistance

across stator sockets 1-2, 2-3 and 3-1.

5. Test for resistance with ohmmeter set on the ohms scale.

a. Resistance across all the stator sockets should be

0.1-0.2 ohms.

b. If the resistance is higher, the stator is damaged and

must be replaced.

c. If the resistance is lower, it could indicate turn to turn

short.

NOTE

Verify that meter reads 0 ohms when probes are shorted

together. If not, subtract lowest value to resistance value of

Figure 1-17. Check for Stator Resistance (Typical)

stator.

1-24 2008 Touring Diagnostics: Starting / Charging

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