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Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 35

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STARTER TROUBLESHOOTING

1.1

Table 1-1. Starter Does Not Run or Runs At Very Low Speeds

SOURCE OF

PROBABLE CAUSE

SOLUTION

PROBLEM

Voltage drop due to discharged battery.

Charge battery.

Battery

Short-circuited or open between electrodes.

Replace battery.

Poor contact condition of battery terminal(s).

Clean and retighten.

Poor or no connection at either battery positive or

Repair or replace cable(s).

negative cable, at either end.

Wiring

Cracked or corroded battery cable ends.

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

Open wire(s) or poor connection at handlebar

Tighten connections or repair or replace wire(s).

switch or starter relay, especially relay ground wire.

Handlebar

Poor switch contacts or open switch.

Replace switch.

start switch

Open coil winding.

Replace relay.

Poor or no continuity at relay points.

Replace relay.

Starter relay

Check for open on wire to TSM/TSSM. Correct

TSM/TSSM has disabled starter relay.

lack of ground.

Polish contact surface or replace solenoid

Poor contact condition caused by burnt contact.

assembly.

Solenoid

Pull-in winding open or short-circuited.

Repair or replace solenoid assembly.

Hold-in winding open or short-circuited.

Repair or replace solenoid assembly.

Check brush spring tension. Replace field frame

Brushes worn below specification.

and holder.

Commutator burnt.

Re-face or replace.

Commutator high mica.

Correct by undercutting.

Field winding grounded.

Replace.

Starting motor

Armature winding grounded or short-circuited.

Replace.

Reduction gears damaged.

Replace.

Insufficient brush spring tension.

Replace.

Disconnected lead wire between solenoid and field

Repair or replace lead wire.

windings.

Ball bearing sticks.

Replace bearing.

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1-1

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Table 1-2. Pinion Does Not Engage With Ring Gear

While Starter is Cranked or Engine Cannot Be Cranked

SOURCE OF

PROBABLE CAUSE

SOLUTION

PROBLEM

Voltage drop due to discharged battery.

Charge battery.

Battery

Short-circuited or open between electrodes.

Replace battery.

Poor contact condition of battery terminal(s).

Clean and retighten.

Overrunning clutch malfunction (rollers or compres-

Replace overrunning clutch.

sion spring).

Pinion teeth worn out.

Replace pinion.

Overrunning

Pinion does not run in overrunning direction.

Replace overrunning clutch.

clutch.

Remove foreign materials, dirt or replace over-

Poor sliding condition of spline teeth.

running clutch or pinion shaft.

Reduction gears damaged.

Replace overrunning clutch and idler gear.

Jackshaft

Improper jackshaft parts assembly.

Disassemble and assemble parts properly.

assembly

Gear teeth on

Excessively worn teeth.

Replace clutch shell.

clutch shell

Table 1-3. Starter Does Not Stop Running

SOURCE OF

PROBABLE CAUSE

SOLUTION

PROBLEM

Unopened contacts.

Replace starting switch or starter relay.

Starting switch or

Poor return caused by sticky switch

starter relay.

Replace starting switch or starter relay.

or relay contacts.

Gear teeth on

Excessively worn teeth.

Replace clutch shell.

clutch shell

Return spring worn.

Replace spring.

Solenoid.

Coil layer shorted.

Replace solenoid.

Contact plate melted and stuck.

Replace solenoid.

1-2

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STARTING SYSTEM DIAGNOSIS

1.2

4.

See Section

1.5 STARTER SYSTEM TESTING,

DIAGNOSTICS

STARTER CURRENT DRAW TEST.

5.

See Section

1.6 TESTING ASSEMBLED STARTER,

FREE RUNNING CURRENT DRAW TEST.

Diagnostic Notes

6.

Connect BREAKOUT BOX (Part No. HD-42682) to TSM/

The reference numbers below correlate with the circled num-

TSSM. See BREAKOUT BOX, TSM/TSSM.

bers on the starter system flow charts.

7.

Connect BREAKOUT BOX (Part No. HD-42682) (black)

and

6-pin Harness Adapters

(Part no. HD-42962)

1.

See Section 1.4 DIAGNOSTICS/TROUBLESHOOTING,

between wiring harness connector [22A] and Right Hand

VOLTAGE DROPS.

Control harness connector [22B] (adapters not used on

2.

Remove starter motor. Connect jumper wires as

FLHR/C/S models).

described under Section 1.6 TESTING ASSEMBLED

STARTER, FREE RUNNING CURRENT DRAW TEST.

Job/Time Code Values

3.

Remove TSSM and use HARNESS CONNECTOR TEST

Dealership technicians filing warranty claims should use the

KIT (Part No. HD-41404A) to short Pin 9 on connector

job/time code values

printed in bold text underneath the

[30] to ground. If starter motor cranks, replace TSSM.

appropriate repair.

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?

5822

YES

YES

YES

NO

STARTER

STARTER

STARTER

Check for audible

RUNS ON.

SPINS, BUT

STALLS OR

clicking noise.

DOES NOT

SPINS TOO

ENGAGE.

SLOWLY.

Disconnect solenoid relay ter-

minal from solenoid. Is 12V

present on GN wire with starter

See Starter Testing 5: Starter

See Starter Testing 6: Starter

Solenoid clicks. See Starter

button not pressed?

Spins, But Does Not Engage.

Stalls or Spins Too Slowly.

Testing 2: Solenoid Clicks.

OR

YES

NO

Relay clicks. See

Is 12V present on starter relay

Replace

Starter Testing 3: Relay Clicks.

Terminal 86 with starter button

solenoid.

not pressed?

5845

OR

Nothing clicks. See Starter

YES

NO

Testing 4: Nothing Clicks.

Replace

Replace

starter button.

starter relay.

5818

5832

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Starter Testing 2: Solenoid Clicks

Perform voltage drop tests between

battery and relay terminal on solenoid.

Less than 1.0 volt?

YES

NO

Perform voltage drop tests from

Backtrack to pinpoint poor

1

1

battery positive to starter motor

connections or relay contact

terminal. Crank engine. Voltage

problems using voltage drop

greater than 1 volt?

tests.

5823

YES

NO

Perform voltage drop tests from

Perform voltage drop tests

1

1

battery positive to starter battery

between battery negative and

terminal. Crank engine. Voltage

starter studs or bolts. Voltage

greater than 1 volt?

greater than 1 volt?

NO

STOP

YES

NO

YES

Go to Starter Testing 3:

Relay Clicks. Begin with

box marked with bold

Repair connection

Repair or replace

Clean ground

asterisk.

between battery and

solenoid (contacts).

connections.

starter.

5845

5824

5824

Starter Testing 3: Relay Clicks

Test for voltage at solenoid relay terminal

on starter. Is 12V present when

starter button is pressed?

YES

NO

Does starter motor

Test for voltage to relay. Is 12V

2

*

turn if jumped?

present on relay terminal 30?

YES

NO

YES

NO

Perform solenoid

Replace or repair

Test for voltage from relay.

Repair open on R/BK

hold-in, pull-in tests. See

starter motor.

Is 12V present on relay

wire feeding Terminal 30

1.6 TESTING ASSEM-

Terminal 87 when starter

on starter relay.

BLED STARTER.

5817

button is pressed?

Solenoid OK?

5827

YES

NO

YES

NO

Mechanical binding or

Replace

Repair open on

Replace

seal binding on jackshaft

solenoid.

GN wire between relay

starter relay.

(dirt or corrosion).

and solenoid.

5860

5832

5850

5827

1-4

2006 Touring: Starting & Charging

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Starter Testing 4: Nothing Clicks

Do turn signals work properly?

YES

NO

With ignition switch ON and

Is Connector [30] fully mated?

starter button depressed, check

for battery voltage from starter

button to relay Terminal 86.

Battery voltage present?

YES

NO

Continuity to ground on

Mate Connector [30].

6

Pin 12 of TSM/TSSM?

6792

YES

NO

Continuity on Pin 1 to

Repair open.

battery fuse?

6805

YES

NO

Continuity on Pin 2 to

Repair open.

Ignition fuse?

6806

YES

NO

Sidecar BAS installed?

Repair open.

6793

YES

NO

See Section 3.20 DTC

Replace TSM/TSSM.

B1151, B1152, B1153.

6791

YES

NO

Check for ground at relay Terminal

Check for battery voltage from

7

85. Ground present?

starter button, terminal 6 (black). Bat-

tery voltage present with starter but-

ton pressed?

YES

NO

YES

NO

Substitute good

Check for continuity from relay

relay or test relay.

Terminal 85 to Pin 9 on

TSSM connector [30].

5832

Repair wiring

Check for battery voltage to starter

Continuity present?

from starter

button, terminal 4 (black). Battery volt-

button to relay.

age present?

5831

YES

NO

Check for voltage on

Repair

YES

NO

3

TSM/TSSM Pin 9 with

open.

key ON. Voltage

present?

5828

Replace

Repair wiring to

starter button.

starter button.

5818

5831

YES

NO

Locate and repair

Replace TSM/TSSM. See Touring

short to voltage.

Models Service Manual.

5830

5838

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1-5

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Starter Testing 5: Starter Spins, But Does Not Engage

Remove and disassemble starter jackshaft

assembly. Is jackshaft properly assembled?

YES

NO

Remove starter. Disassemble drive housing

Assemble jackshaft

assembly. Inspect for damage to armature

properly.

gear or idler gear. Damage present?

5850

YES

NO

Replace damaged idler

Starter clutch failure.

gear and armature.

Replace starter clutch.

5825

5837

Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery

1

positive to starter motor terminal. Crank

engine. Voltage greater than 1 volt?

YES

NO

Perform voltage drop tests

Perform voltage drop tests

1

between battery positive to

between battery negative and

starter battery terminal.

starter studs or bolts.

Crank engine.

Voltage greater than 1 volt?

Voltage greater than 1 volt?

YES

NO

YES

NO

Clean ground

Perform starter motor current

4

Repair connection

Repair or replace

connections.

draw test (on vehicle).

between battery and

solenoid (contacts).

5835

starter.

Perform starter motor free draw

5

5845

bench test.

5824

Are test results within range?

YES

NO

Remove spark plugs while in

Replace or repair

5th gear. Rotate rear wheel.

starter motor.

Check for engine, primary

and/or crankshaft bind.

5817

Use appropriate code

1-6

2006 Touring: Starting & Charging

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STARTER ACTIVATION CIRCUITS

1.3

s0593x8x

1

1

ITEM A

ITEM B

IDEAL CLOSED

0.1A

0.1A

0.1A

0.1A

2

2

CIRCUIT

8

8

20A

20A

7

7

OV

20A

20A

6

6

VDC

3

4

3

4

5

5

200A

200A

200A

200A

1

1

ITEM C

ITEM D

0.1A

0.1A

OPEN CIRCUIT

0.1A

0.1A

GROUND CIRCUIT

2

2

8

8

20A

20A

20A

VDC

7

7

12V

OV

20A

6

6

VDC

3

4

5

3

4

5

200A

200A

200A

200A

1.

Start switch

5.

Battery

2.

Relay

6.

Maxi fuse

3.

Solenoid

7.

Ignition switch

4.

Starter

8.

Ignition fuse

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

2006 Touring: Starting & Charging

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STARTER SYSTEM TESTING

1.5

GENERAL

NOTE

FLHX, FLHT/C/U, FLTR

Check the wire tags for positive

identification of relays. Starter

Before removing the starter, perform one of the Starter Relay

relay can be positively identified

by heavy gauge Green wire.

Tests which follow. If the relay is known to be good, perform

Ignition Keyswitch

the STARTER CURRENT DRAW TEST in this section.

Relay [126]

Starter

Relay [123]

STARTER RELAY TEST 1

1.

Remove relay. For FLHR/C/S models, see upper frame

of Figure 1-2. For all other models, see upper frame of

Figure 1-3.

2.

Substitute a new relay known to be good and verify oper-

ation. For convenience, use the brake light relay as a

temporary substitute on FLHR/C/S models, or use the

ignition keyswitch relay as a temporary substitute on

FLTR and FLHT/C/U models.

f2192x8x

FLHR/C/S

f1333x2x

Ohmmeter

Brake Light

Relay [124]

87

O

86

85

Battery

87A

30

Figure 1-3. Locate Relay Under Seat

Starter

Relay [123]

f2210x8x

STARTER RELAY TEST 2

The starter relay can be tested using the vehicle’s 12 volt bat-

f1741x5x

Ohmmeter

tery and a continuity tester or ohmmeter (HD-35500B). Pro-

ceed as follows:

1.

Remove relay. For FLHR/C/S models, see upper frame

O

of Figure 1-2. For all other models, see upper frame of

Figure 1-3.

86

87A

85

Battery

2.

To energize the relay, connect the battery leads to termi-

87

nals 86 and 85. For FLHR/C/S models, see lower frame

30

of Figure 1-2. For all other models, see lower frame of

Figure 1-3.

Figure 1-2. Locate Relay Under Left Side Cover

3.

Check for continuity between terminals 30 and 87.

2006 Touring: Starting & Charging

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4.

If the tester lamp illuminates or there is a zero ohm read-

ing on the ohmmeter, then continuity is present and the

relay is good. Replace the relay if continuity is not

Induction

Ammeter

present.

CAUTION

Relay terminal “85” must be connected to the negative

battery terminal to avoid damaging the diode connected

across the relay winding.

STARTER CURRENT DRAW TEST

Battery

Check the starter current draw with an inductive amp probe

(HD-39617) or induction ammeter. Before proceeding, be

sure that the battery is fully charged and that the engine tem-

“Battery”

perature is stable and at room temperature.

f1334x2x

Terminal

1.

Verify that the transmission is in neutral.

Figure 1-4. Starter Current Draw Test

2.

Disconnect the spark plug wires from the spark plug ter-

minals.

3.

Clamp induction ammeter over the positive battery cable.

b. If the starter current draw exceeds 250 amperes, the

See Figure 1-4.

problem may be in the starter or starter drive.

4.

With the ignition ON, turn the engine over by pressing

start switch while taking a reading on the ammeter. Dis-

5.

Remove the starter for testing, if necessary. See the

regard initial high current reading which is normal during

Touring Models Service Manual, STARTER, REMOVAL.

time the engine is first turned over.

6.

See Section

1.6 TESTING ASSEMBLED STARTER,

a. Typical starter current draw will range between 160

FREE RUNNING CURRENT DRAW TEST.

and 200 amperes.

1-10

2006 Touring: Starting & Charging

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TESTING ASSEMBLED STARTER

1.6

STARTER SOLENOID

Relay

Motor

Terminal

Terminal

1WARNING

Wear eye protection during this series of tests. These

tests may produce flying sparks which could result in

death or serious injury.

NOTE

Do not disassemble solenoid. Before testing, disconnect field

Battery

wire from motor terminal as shown in Figure 1-5.

CAUTION

b0161a5x

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

prevent damage to solenoid.

Figure 1-5. Test 1: Pull-In Test

NOTE

Relay

b0162a5x

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

Motor

Terminal

formed together in one continuous operation. Conduct all

Terminal

three tests one after the other in the sequence listed.

SOLENOID PULL-IN TEST

1.

See Figure 1-5. Using a 12 volt battery, connect three

separate test leads as follows:

Battery

a. Solenoid housing to negative battery post.

b. Solenoid motor terminal to negative battery post.

c. Solenoid relay terminal to positive battery post.

2.

Observe starter shaft.

Figure 1-6. Test 2: Hold-In Test

a. If starter shaft extends strongly, solenoid is working

properly.

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

2.

Observe starter shaft.

solenoid.

a. If starter shaft remains extended, solenoid is work-

ing properly.

SOLENOID HOLD-IN TEST

b. If starter shaft retracts, replace the solenoid.

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

1.

See Figure 1-6. With test leads still connected in the

manner specified in the previous SOLENOID PULL-IN

TEST, disconnect solenoid motor terminal/battery nega-

tive test lead (B) at negative battery post only; reconnect

loose end of this test lead to positive battery post

instead.

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SOLENOID RETURN TEST

b0163a5x

Relay

Motor

Terminal

1.

See Figure 1-7. With test leads still connected in the

Terminal

manner specified at the end of the previous SOLENOID

HOLD-IN TEST, disconnect solenoid relay terminal/posi-

tive battery post test lead (C) at either end.

2.

Observe starter pinion.

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

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

Battery

FREE RUNNING CURRENT

DRAW TEST

Figure 1-7. Test 3: Return Test

1.

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

b0439x5x

scratches or other damage.

2.

Connect a heavy jumper cable (6 gauge minimum) to

2

starter mounting flange as shown in Figure 1-8.

3.

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

1

charged battery.

5

4.

Connect a heavy jumper cable (6 gauge minimum) to the

positive (+) terminal of the battery.

5.

Attach an inductive ammeter to positive cable and con-

nect the other end of the positive cable to the “Battery”

3

terminal of the starter solenoid.

4

6.

Use a smaller jumper cable (14 gauge) and connect to

the positive (+) terminal of the battery.

1.

Mounting flange

7.

Connect other end of small jumper cable to the solenoid

2.

Battery

“Relay” terminal.

3.

Induction ammeter

8.

Check ammeter reading. Ammeter should show 90 amps

4.

Battery terminal

maximum. If reading is higher, disassemble starter for

5.

Relay terminal

inspection.

Figure 1-8. Free Running Current Draw Test

NOTE

If starter current draw on vehicle was over 200 amps and the

starter FREE RUNNING CURRENT DRAW TEST was within

specification, there may be a problem with engine, primary

drive or starter jackshaft.

1-12

2006 Touring: Starting & Charging

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CHARGING SYSTEM

1.7

GENERAL

TROUBLESHOOTING

The charging system consists of the alternator and voltage

When the charging system fails to charge or does not charge

regulator. Charging system circuits are shown in Figure 1-9.

at a satisfactory rate, it is recommended that the following

checks be made.

Alternator

The alternator consists of two main components:

Battery

● the rotor mounted on the engine sprocket shaft

● the stator bolted to the engine crankcase.

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

TESTING for battery testing procedures. Battery must be fully

charged in order to perform a load test, or starting or charging

Voltage Regulator

tests. However, a partially discharged battery may be tested

The voltage regulator is a series regulator with a circuit that

using the BATTERY TEST function of the ADVANCED BAT-

combines the functions of rectifying and regulating. See Fig-

TERY CONDUCTANCE AND ELECTRICAL SYSTEM ANA-

ure 1-10.

LYZER (HD-48053).

STATOR

[77B]

[77A]

[46A]

[46B]

2

BK

BK

DC AC

BK

1

40 A

MAXI-FUSE

B A

R

BK

BK

RED

LEFT

BAND

DIRTY GND

POWERTRAIN

STARTER

BATTERY

f2430x8x

GROUNDS

Figure 1-9. Charging System Circuit (Typical)

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Job/Time Code Values

f2417x8x

Dealership technicians filing warranty claims should use the

job/time code values printed in bold text underneath the

appropriate repair.

2

1

1.

Stator (AC) Connector [46A]

2.

Voltage Regulator (DC) Connector [77A]

Figure 1-10. Voltage Regulator (Bottom View)

AC and DC Connectors

Wiring

See charging system circuit in Figure 1-9. Check for corroded

or loose connections.

Voltage Regulator Inspection

The regulator must have a clean, tight ground connection for

proper operation. Using an ohmmeter with one lead on the

battery ground cable and the other on the regulator ground

terminal, check with the voltage regulator DC connector dis-

engaged. The electrical continuity test is performed with the

ohmmeter set to the RX1 scale. A resistance value below 1

ohm should be observed.

1-14

2006 Touring: Starting & Charging

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Test 1.7 (Part 1 of 2)

SYMPTOM: BATTERY BECOMES DISCHARGED

Test battery.

Charge or replace as required.

Inspect regulator.

See Voltage Regulator Inspection.

PASS

FAIL

Perform MILLIAMP DRAW

Correct as

TEST (If applicable).

required.

5306

PASS

FAIL

Perform TOTAL CURRENT

Isolate damaged

DRAW TEST.

component or wiring.

Record measurement.

5308

PASS

FAIL

Isolate damaged wiring or

excessive accessories.

STOP

5310

Go to Test 1.7

(Part 2 of 2).

NOTE

Whenever a charging system component fails a test and

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

been corrected.

2006 Touring: Starting & Charging

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Test 1.7 (Part 2 of 2)

SYMPTOM: BATTERY BECOMES DISCHARGED

From Test 1.7 (Part 1 of 2).

Perform CURRENT OUTPUT TEST. Record

measurement and compare with TOTAL CUR-

RENT DRAW TEST before proceeding.

PASS

FAIL

Perform VOLTAGE

Perform

OUTPUT TEST.

STATOR CHECK.

PASS

FAIL

PASS

FAIL

Replace

Perform

Replace

System tests good up to this point. Suspect:

Regulator.

AC OUTPUT CHECK.

Stator.

Accessories on for long periods when vehicle is

5316

5312

parked and not running.

Accessories on when vehicle is ridden very slowly

for long periods.

PASS

FAIL

Battery self-discharge and/or accessory draw

because vehicle was not operated for a long

period.

Replace Regulator.

Inspect Rotor.

Perform CURRENT

OUTPUT TEST.

5315

PASS

FAIL

PASS

FAIL

System

Damaged or

Replace

Replace

OK.

Slipping Rotor.

Stator.

Rotor.

5319

5314

5319

NOTE

Whenever a charging system component fails a test and

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

been corrected.

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2006 Touring: Starting & Charging

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TESTING

TOTAL CURRENT DRAW TEST

If the battery runs down during use, the current draw of the

motorcycle components and accessories may exceed the

MILLIAMP DRAW TEST

output of the charging system. To check for this condition,

NOTES

place load tester induction pickup or current probe pickup

over battery negative cable as shown in Figure 1-12. Discon-

● Be sure accessories are not wired so they stay on at all

nect regulator from stator. Start engine and run at 3000 rpm.

times. Check for this by connecting ammeter between

negative battery terminal and battery.

With ignition and all continuously running lights and accesso-

ries turned on (headlamp on high beam), read the total cur-

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

rent draw. Compare this reading to the reading obtained in

onds after ignition is turned OFF. Any disruption and

CURRENT OUTPUT TEST. The current output should

reconnection of battery power, such as disconnecting the

exceed current draw by 3.5 amps, minimum. If not, there may

battery to place a meter in series, will cause TSM/TSSM

be too many accessories for the charging system to handle.

to draw 16-25 mA for 30 seconds.

Reconnect regulator when test is complete.

See Figure 1-11. Remove maxi-fuse. Connect ammeter using

NOTE

HARNESS CONNECTOR TEST KIT (HD-41404A) red pin

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

probes and patch cords. With this arrangement, you will also

pick up any regulator drain.

The limits for these drains are listed in Table 1-4.

f2333x8x

● Any accessories must be considered and checked for

AMMETER

excessive drain.

● This condition could drain battery completely if vehicle is

parked for a long time.

MAXI-FUSE HOLDER

NOTES

B A

● A battery with surface discharge condition could cause a

static drain. Correct by cleaning battery case.

TO MAIN HARNESS

R

R

● Any reading that exceeds the “Average Meter Reading”

BK

BK

values below indicates excessive current draw. Check for

bad radio, voltage regulator or short in the interconnect-

ing wiring. Alarms and customer accessories are also

prime suspects. Isolate problem by disconnecting sus-

POWERTRAIN

STARTER

pect components and observe change in meter reading.

GROUNDS

BATTERY

Figure 1-11. Milliamp Draw Test

Table 1-4. Milliampere Draw Test

(Ignition Switch OFF)

Load

DRAW IN MILLIAMPERES

COMPONENT

Tester

Average Meter Reading

ECM (EFI models)

1.0

Speedometer

0.5

Tachometer

0.5

TSM (no security)

0.5

TSSM (armed)

3.0

TSSM (disarmed)

3.0

TSSM (storage mode)

0.5

Security Siren (Optional)

20.0*

Voltage Regulator

2.0

Radio

2.0

High Output Amplifier

0.2

d0004x8x

CB Module

0.4

XM Module

0.1

Figure 1-12. Check Current Draw (Ignition Switch On)

* 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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See Figure 1-13. The analyzer printer will provide a printout

x0665x1x

including one of two possible test results:

● CHARGING SYSTEM NORMAL-No problem found.

CHARGING TEST

PROBLEM

● CHARGING SYSTEM PROBLEM-The analyzer

LOW

detected a problem and will display one of the three fol-

CHARGING VOLTS

lowing results:

IDLE:

12.32V

a. LOW CHARGING VOLTS-the alternator is not sup-

REV:

12.32V

plying sufficient current for the system’s electrical

REFER TO H-D

loads.

SERVICE MANUAL

b. HIGH CHARGING VOLTS-The voltage output from

the alternator exceeds the normal regulator limits.

c. INVESTIGATE VOLT OUTPUT-The rev voltage is

Figure 1-13. Charging System Test Results-Printout

lower than the idle voltage.

LOAD TESTER

Load

Tester

1.

Connect load tester negative and positive leads to bat-

tery terminals and place load tester induction pickup over

positive regulator cable as shown in Figure 1-14.

2.

Run the engine at 3000 rpm and increase the load as

To Maxi-Fuse

required to obtain a constant 13.0 volts DC.

(DC Output)

3.

The current output should be 45-60 amps.

VOLTAGE OUTPUT TEST

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

voltage meter. Voltage to the battery must be less than 15

volts. If voltage is higher, the voltage regulator is not function-

ing properly or connections are loose or dirty.

CAUTION

Do not leave any load switch turned on for more than 20

seconds or overheating and tester damage are possible.

To Voltage

f1314x8x

Regulator

STATOR CHECK

Grounded Stator

Figure 1-14. Current and Voltage Output Test

1.

Turn ignition keyswitch OFF.

2.

Connect ohmmeter as follows:

CURRENT OUTPUT TEST

a. Disconnect stator from voltage regulator.

b. Insert ohmmeter probe into one of the three stator

For this test, you may use either the ADVANCED BATTERY

connector sockets. See Figure 1-15.

CONDUCTANCE AND ELECTRICAL SYSTEM ANALYZER

(HD-48053) or a load tester.

c. Attach the other ohmmeter probe to a suitable

ground point on the engine. Check several places to

ensure good continuity is made.

ELECTRICAL SYSTEM ANALYZER

3.

Test for continuity between all three stator connector

1.

Connect the analyzer leads to the battery.

sockets and the ground point with ohmmeter.

2.

Follow the instructions in the analyzer instruction manual

a. A GOOD stator will show a large resistance to

to perform a charging system test.

ground (infinite ohms) between stator socket and

The test results will include a decision on the condition of the

ground.

charging system and the measured output voltage at idle and

b. A BAD stator will show continuity between stator

at 3000 RPM.

socket and ground.

4.

Replace stator if grounded (BAD).

1-18

2006 Touring: Starting & Charging

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