Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 28
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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.
Cracked or corroded battery cable ends.
Clean, tighten or replace cable(s) as needed.
Wiring
Open wire(s) or poor connection at handlebar
switch or starter relay, especially relay ground wire
Tighten connections or repair or replace wire(s).
(grounds through TSM/TSSM).
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.
2006 Sportster: Starting & Charging
1-1
HOME
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.
Gear teeth on
Replace clutch shell.
Excessively worn teeth.
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
2006 Sportster: Starting & Charging
HOME
STARTING SYSTEM DIAGNOSIS
1.2
DIAGNOSTICS
1. Motor terminal
2. Battery terminal
3. Relay terminal
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the starter system flow charts.
3
1. See VOLTAGE DROPS under
1.4 DIAGNOSTICS/
1
TROUBLESHOOTING.
2. Remove starter motor. Connect jumper wires as
described under FREE RUNNING CURRENT DRAW
2
TEST under 1.6 TESTING STARTER ON BENCH.
3. Connect BREAKOUT BOX (Part No. HD-42682) to TSM/
TSSM. See 3.11 BREAKOUT BOX: TSM/TSSM.
x0533x1x
4. Remove TSSM and use HARNESS CONNECTOR TEST
Figure 1-1. Starter Terminals
KIT (Part No. HD-41404) to short terminal 9 on connec-
tor [30] to ground. If starter motor cranks, replace TSSM.
5. Connect BREAKOUT BOX (Part No. HD-42682) (black)
and
6-pin Harness Adapters
(Part No. HD-42962)
between wiring harness connector [22A] and right hand
control harness connector [22B].
6. See STARTER CURRENT DRAW TEST under 1.5
TESTING STARTER ON MOTORCYCLE.
7. See FREE RUNNING CURRENT DRAW TEST under
1.6 TESTING STARTER ON BENCH.
2006 Sportster: Starting & Charging
1-3
HOME
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
terminal from solenoid.
Is 12V present on GN wire with
See Starter Testing 5: Starter
See Starter Testing 6: Starter
Solenoid clicks. See Starter
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 1 with starter button
solenoid.
not pressed?
5845
OR
YES
NO
Nothing clicks. See Starter
Testing 4: Nothing Clicks.
Replace
Replace
starter button.
starter relay.
5818
5832
1-4
2006 Sportster: Starting & Charging
HOME
Starter Testing 2: Solenoid Clicks
Perform voltage drop tests between
battery and relay terminal on solenoid.
Is voltage drop less than 1.0 volt?
YES
NO
1
1
Perform voltage drop tests from
Backtrack to pinpoint poor
battery positive to starter motor
connections or relay contact
terminal. Crank engine.
problems using voltage drop tests.
Is voltage drop greater than 1.0 volt?
5823
YES
NO
1
1
Perform voltage drop tests from
Perform voltage drop tests
battery positive to starter battery
between battery negative and
terminal. Crank engine.
starter studs or bolts.
Is voltage drop greater than 1.0 volt?
Is voltage drop greater than 1.0 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
2
Does starter motor
Test for voltage to relay.
turn if jumped?
*
Is 12V present on relay terminal 3?
YES
NO
YES
NO
Replace
Replace or repair
Test for voltage from relay.
Repair open on R/BK
solenoid.
starter motor.
Is 12V present on relay
wire feeding terminal 3
terminal 5 when starter
on starter relay.
5860
5817
button is pressed?
5827
YES
NO
Repair open on
Replace
GN wire between relay
starter relay.
and solenoid.
5832
5827
2006 Sportster: Starting & Charging
1-5
HOME
Starter Testing 4: Nothing Clicks
Do turn signals work
properly?
NO
YES
Is connector [30] fully mated?
With ignition switch ON and starter
YES
NO
button depressed, check for
3
battery voltage at relay Terminal 1
from starter button.
Is continuity to ground
Mate connector [30].
Is battery voltage present?
present on pin 12?
6792
YES
NO
Is continuity on pin 1 to
Repair open.
battery fuse present?
6805
YES
NO
Is continuity on pin 2 to
Repair open.
ignition fuse present?
6806
YES
NO
Replace
TSM/TSSM.
Repair open.
6791
6793
YES
NO
5
Check for ground at
Check for battery voltage from
relay Terminal 2.
starter button, terminal 6 (black).
Is ground present?
Is battery voltage present with
starter button pressed?
YES
NO
YES
NO
Replace starter
Check for continuity from relay
relay.
Terminal 2 to Pin 9 on
TSM/TSSM connector [30].
Repair wiring
Check for battery voltage to starter
5832
Is continuity present?
from starter
button, terminal 4 (black). Is battery
button to relay.
voltage present?
5831
YES
NO
4
Check for voltage on
Repair
YES
NO
TSM/TSSM Pin 9
open.
with key ON.
Is voltage present?
5828
Replace
Repair wiring to
starter button.
starter button.
YES
NO
5818
5831
Locate and repair
short to voltage.
Replace TSM/TSSM. See
Sportster Service Manual.
5830
5838
1-6
2006 Sportster: Starting & Charging
HOME
Starter Testing 5: Starter Spins But Does Not Engage
Remove starter. Disassemble drive
housing assembly. Inspect for damage
to armature gear or idler gear.
Is damage present?
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
1
Perform voltage drop tests from battery
positive to starter motor terminal. Crank engine.
Is voltage drop greater than 1.0 volt?
YES
NO
1
1
Perform voltage drop tests between
Perform voltage drop tests
battery positive to starter battery
between battery negative and
terminal. Crank engine.
starter studs or bolts.
Is voltage drop greater than 1.0 volt?
Is voltage drop greater than 1.0 volt?
YES
NO
YES
NO
6
Repair connection
Repair or replace
Clean ground
Perform starter motor current
between battery and
solenoid (contacts).
connections.
draw test (on vehicle).
7
starter.
5845
5835
Perform starter motor free
5824
running current draw bench test.
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
2006 Sportster: Starting & Charging
1-7
HOME
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
20A
8
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.
Main fuse
3.
Solenoid
7.
Ignition switch
4.
Starter
8.
Ignition fuse
Figure 1-2. Typical Circuity. Refer to wiring diagrams for more information.
1-8
2006 Sportster: Starting & Charging
HOME
DIAGNOSTICS/TROUBLESHOOTING
1.4
5.
Typically, a good circuit will drop less than 1.0 volt. If the
GENERAL
voltage drop is greater, back track through the connec-
tions until the source of the potential difference is found.
The troubleshooting tables beginning on page 1-1 contain
The benefits of doing it this way are speed and accuracy.
detailed procedures to solve and correct problems. Follow the
a. Readings aren’t as sensitive to real battery voltage.
1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose
starting system problems. The VOLTAGE DROPS procedure
b. Readings show the actual voltage dropped, not just
below will help you to locate poor connections or components
the presence of voltage.
with excessive voltage drops.
c. This tests the system as it is actually being used. It
is more accurate and will display hard to find poor
connections.
VOLTAGE DROPS
d. This approach can be used on lighting circuits, igni-
tion circuits, etc. Start from most positive and go to
Check the integrity of all wiring, switches, fuses and connec-
most negative (the destination or component).
tors between the source and destination.
6.
See ITEM D in Figure 1-2. The negative or ground circuit
The voltage drop test measures the difference in potential or the
can be checked as well.
actual voltage dropped between the source and destination.
a. Place the negative lead on the most negative part of
1. See ITEM A in Figure 1-2. Attach your red meter lead to
the circuit (or the negative battery post). Remember,
the most positive part of the circuit, which in this case
there is nothing more negative than the negative
would be the positive post of the battery (5).
post of the battery.
2. See ITEM B in Figure 1-2. Attach the black meter lead to
b. Place the positive lead to the ground you wish to
check.
the final destination or component in the circuit (solenoid
terminal from relay).
c. Activate the circuit. This will allow you to read the
potential difference or voltage dropped on the nega-
3. Activate the starter and observe the meter reading. The
tive or ground circuit. This technique is very effective
meter will read the voltage dropped or the difference in
for identifying poor grounds due to powdered paint.
potential between the source and destination. An ideal
Even the slightest connection may cause an ohm-
circuit’s voltage drop would be
0 volts or no voltage
meter to give a good reading. However, when suffi-
dropped, meaning no difference in potential.
cient current is passed through, the resistance
4. See ITEM C in Figure 1-2. An open circuit should read
caused by the powdered paint will cause a voltage
12 volts, displaying all the voltage dropped, and the
drop or potential difference in the ground circuit.
entire difference in potential displayed on the meter.
NOTE
Open circuits on the ground side will read zero.
2006 Sportster: Starting & Charging
1-9
BK
BATTERY
HAND CONTROLS,
RIGHT
IGNITION SWITCH LEGEND
[162]
SWITCH
RED/BLACK
RED
RED/GRAY
POSITION
OFF
ACC.
IGNITION
RIGHT TURN SWITCH
DOT INDICATES CONTINUITY WITH RED
STARTER
ENGINE STOP/RUN
SWITCH
WIRE IN SWITCH POSITION INDICATED
START SWITCH
30 AMP
STOPLIGHT SWITCH
IGN
MAXIFUSE
SWITCH
[33]
[5B]
[22B]
6 5 4
3
2
1
B A
6
5
4 3
2
1
[22A]
R
[61B]
TURN SIGNAL/SECURITY MODULE
IGNITION - 15A
A
B
GY
GY
R/BK
BATTERY
1
BN/GY
IGNITION
2
GY
VSS / SERIAL DATA LINK
3
SECURITY INDICATOR
4
LEFT TURN FEED
5
RIGHT TURN FEED
6
RIGHT TURN SWITCH INPUT
7
LEFT TURN SWITCH INPUT
8
START RELAY CONTROL
9
TN/GN
IGNITION ENABLE SIGNAL
10
ALARM SIGNAL
11
J
BATTERY - 15A
I
GROUND
12
BK
BN/GY
R
TS/TSSM
[30A][30B]
4
5 1 2 3
T
K U S E
BK/R
R/BK
TN/GN
POWERTRAIN
GN
GROUND
POINT
START RELAY
ACCESSORY
IGNITION
[GND1]
D
C
B
15A
A
E
15ABATTERY
INSTRUMENTS
J
H
G
K
15A
15A
LIGHTS
SPARE
U T S
R
P
O
M
Wire Color Code Key
15A
BK- Black
GN - Green
LT.GN - Light Green
PIN CONNECTOR
(A side)
[61] TOP VIEW
BN - Brown
BE - Blue
PK - Pink
R - Red
V-/ Violet
TN - Tan
SOCKET CONNECTOR
O - Orange
GY - Gray
Wire color-XX/XX-Stripe color
(B side)
Y - Yellow
W - White
HOME
TESTING STARTER ON MOTORCYCLE
1.5
STARTER RELAY TEST
10062
1
1. Remove left side cover.
2. See Figure 1-4. Locate starter relay (1) in upper corner
of oil tank on motorcycle’s left side.
3. To test relay, proceed to Step 4. If installing a new starter
relay, unplug old relay from relay/fuse block and replace.
2
CAUTION
Only connect relay terminal 2 to negative battery termi-
nal. Improper connections will damage the diode con-
nected across the relay windings.
4. See Figure 1-5. The starter relay can be tested using the
1.
Starter relay
motorcycle’s 12 volt battery and a multimeter.
2.
Relay/fuse block
a. Unplug relay from relay/fuse block.
Figure 1-4. Starter Relay
b. To energize relay, connect the battery leads to termi-
nals 1 and 2 as shown, battery positive (+) to termi-
nal 1, battery negative (-) to terminal 2.
x0527x1x
1
c. Check for continuity between terminals 3 and 5. A
2
good relay shows continuity (continuity tester lamp
“on” or a zero ohm reading on the ohmmeter). A
malfunctioning relay will not show continuity and
must be replaced.
1
4
2
5. If starter relay is functioning properly, plug it into relay/
5
fuse block and proceed to STARTER CURRENT DRAW
3
TEST.
1. Ohmmeter
3
2. Battery
STARTER CURRENT DRAW TEST
3. Starter relay
Figure 1-5. Starter Relay Test
NOTES
● Engine temperature should be stable and at room tem-
perature.
x0529x1x
● Battery should be fully charged.
Induction
ammeter
See Figure 1-6. Check starter current draw with an induction
ammeter before disconnecting battery. Proceed as follows:
1. Verify that transmission is in neutral. Disconnect spark
plug wires from spark plug terminals.
2. Clamp induction ammeter over positive battery cable
next to starter.
3. With ignition key switch ON, turn engine over by pressing
starter switch while reading the ammeter. Disregard ini-
tial high current reading which is normal when engine is
Battery
first turned over.
a. Typical starter current draw will range from 160 to
200 amperes.
Figure 1-6. Starter Draw Test
b. If starter current draw exceeds 250 amperes, the
problem may be in the starter or starter drive.
Remove starter for further tests. See the Sportster
NOTE
Service Manual.
See Figure 1-6. A DC current probe may be used if an induc-
tion ammeter is not available.
2006 Sportster: Starting & Charging
1-11
HOME
TESTING STARTER ON BENCH
1.6
FREE RUNNING
10656
CURRENT DRAW TEST
1
3
1.
Place starter in vise, using a clean shop towel to prevent
scratches or other damage.
2.
See Figure 1-8. Attach one heavy jumper cable (6 gauge
minimum).
a. Connect one end to the starter mounting flange (1).
b. Connect the other end to the negative (-) terminal of
a fully charged battery (2).
3.
Connect a second heavy jumper cable (6 gauge mini-
mum).
2
a. Connect one end to the positive (+) terminal of the
4
battery (2).
b. Connect the other end to the battery terminal (4) on
the starter solenoid. Place an inductive ammeter (3)
1. Starter motor
over cable.
2. Nut with washer (metric)
4.
Connect a smaller jumper cable (14 gauge minimum).
3. Positive battery cable ring terminal
a. Connect one end to the positive (+) terminal of the
4. Solenoid wire connector [128]
battery (2).
b. Connect the other end to the solenoid relay terminal
Figure 1-7. Starter Wires
(5).
5.
Check ammeter reading.
x0528x1x
a. Ammeter should show 90 amps maximum.
b. If reading is higher, disassemble starter for inspec-
tion. See the Sportster Service Manual.
2
c. If starter current draw on vehicle was over 200 amps
and this test was within specification, there may be a
problem with engine, primary drive or jackshaft.
1
5
STARTER SOLENOID
3
1WARNING
Wear eye protection during this series of tests. These
4
tests may produce flying sparks which could result in
death or serious injury.
1.
Mounting flange
NOTE
2.
Battery
Do not disassemble solenoid. Before testing, disconnect field
3.
Induction ammeter
wire from motor terminal as shown in Figure 1-9.
4.
Battery terminal
5.
Relay terminal
CAUTION
Figure 1-8. Free Running Current Draw Test
Each test should be performed for only 3-5 seconds to
prevent damage to solenoid.
NOTE
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
interruption.
1-12
2006 Sportster: Starting & Charging
HOME
SOLENOID PULL-IN TEST
x0530x1x
1.
See Figure 1-9. Using a 12 volt battery, connect three
1
2
3
separate test leads as follows:
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.
a. If starter shaft extends strongly, solenoid is working
properly.
b. If starter shaft does not extend strongly, replace the
solenoid.
1. Motor terminal
SOLENOID HOLD-IN TEST
2.
Relay terminal
3. Battery
1. See Figure 1-10. With test leads still connected in the
manner specified in the previous SOLENOID PULL-IN
Figure 1-9. Test 1: Pull-In Test
TEST, disconnect solenoid motor terminal/battery
negative test lead (B) at negative battery post only;
reconnect loose end of this test lead to positive bat-
x0531x1x
tery post instead.
2. Observe starter shaft.
1
2
3
a. If starter shaft remains extended, solenoid is work-
ing properly.
b. If starter shaft retracts, replace the solenoid.
SOLENOID RETURN TEST
1. See Figure 1-11. With test leads still connected in the
manner specified at the end of the previous SOLENOID
HOLD-IN TEST, disconnect solenoid relay terminal/
positive battery post test lead (C) at either end.
2. Observe starter pinion.
1.
Motor terminal
2.
Relay terminal
a. If starter shaft retracts, solenoid is working properly.
3.
Battery
b. If starter shaft does not retract, replace the solenoid.
Figure 1-10. Test 2: Hold-In Test
x0532x1x
1
2
3
1.
Motor terminal
2.
Relay terminal
3.
Battery
Figure 1-11. Test 3: Return Test
2006 Sportster: Starting & Charging
1-13
HOME
CHARGING SYSTEM
1.7
GENERAL
10064
The charging system consists of the alternator and regulator.
The charging system circuit is shown in Figure 1-14.
1
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 1-12. The voltage regulator is a series regulator
with shunt control. The circuit combines the functions of recti-
fying and regulating.
2
TROUBLESHOOTING
1.
Voltage regulator
When the charging system fails to charge or does not charge
2.
Connector [77]
at a satisfactory rate, make the following recommended
checks.
Figure 1-12. Voltage Regulator
Battery
Check for a weak or dead battery. See 1.9 BATTERY TEST-
ING for battery testing procedures. Battery must be fully
10065
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 MCR-101 HD Elec-
trical System Tester.
Wiring
Check for corroded or loose connections in the charging cir-
cuit. See Figure 1-14.
Voltage Regulator Inspection
See Figure 1-12. The voltage regulator base must have a
clean, tight connection for proper grounding. Check by using
an ohmmeter with one lead on a known good ground, such as
battery ground cable, and the other on the regulator base.
See Figure 1-13. The stator connector plug and socket con-
Figure 1-13. Stator Connector [46] Plug
nection must be clean and tight.
1-14
2006 Sportster: Starting & Charging
HOME
x0034f7x
STATOR
BK
BK
BATTERY
BK
VOLTAGE
[46B]
REGULATOR
1
2
1
2
[46A]
BK
30 AMP
MAXIFUSE
BK
[5B]
BK
B A
BK
R
R
A
A
BK
B
B
[77B]
[77A]
GND 2
Wire Color Code Key
BK - Black
GN - Green
LT.GN - Light Green
PIN CONNECTOR
(A side)
BN - Brown
BE - Blue
PK - Pink
R - Red
V - Violet
TN - Tan
SOCKET CONNECTOR
O - Orange
GY - Gray
(B side)
Y - Yellow
W - White
Figure 1-14. Charging System Circuit
2006 Sportster: Starting & Charging
1-15
HOME
Charging System Test 1.7 (Part 1 of 2)
SYMPTOM: BATTERY BECOMES DISCHARGED
Test battery.
Charge or replace as required.
Inspect regulator.
See 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 Charging
System Test 1.7
(Part 2 of 2).
NOTE
Whenever a charging system component fails a test and
is replaced, re-test the system to be sure the problem
has been corrected.
1-16
2006 Sportster: Starting & Charging
HOME
Charging System Test 1.7 (Part 2 of 2)
SYMPTOM: BATTERY BECOMES DISCHARGED
From Charging System Test 1.7 (Part 1 of 2).
Perform CURRENT OUTPUT TEST. Record
measurement and compare with TOTAL CURRENT
DRAW TEST before proceeding.
PASS
FAIL
Perform VOLTAGE
Perform
OUTPUT TEST.
STATOR CHECK.
PASS
FAIL
PASS
FAIL
System tests good up to this point. Suspect:
Replace
Perform AC
Replace
regulator.
OUTPUT TEST.
stator.
Accessories on for long periods when vehicle is
parked and not running.
5316
5312
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.
PASS
FAIL
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, re-test the system to be sure the problem
has been corrected.
2006 Sportster: Starting & Charging
1-17
HOME
TESTING
Total Current Draw Test
If battery runs down during use, the current draw of the
motorcycle components and accessories may exceed output
Milliampere Draw Test
of the charging system.
NOTES
NOTE
●
Be sure accessories are not wired so they stay on at all
If a load tester is unavailable, an ammeter with current probe
times. This condition could drain battery completely if
may be used.
vehicle is parked for a long time. Check for this by con-
necting ammeter between negative battery cable and
ground.
1WARNING
●
TSM/TSSM will continue to draw 16-25 mA for 30 sec-
Turn battery load tester OFF before connecting tester
onds after ignition is turned OFF. Any disruption and
cables to battery terminals. Connecting tester cables
reconnection of battery power, such as disconnecting the
with load tester ON can cause a spark and battery explo-
battery to place a meter in series, will cause TSM/TSSM
sion, which could result in death or serious injury.
to draw 16-25 mA for 30 seconds.
(00252a)
●
When ignition is OFF, the ICM draws no current.
1. See Figure 1-16. To check for this condition, place load
tester induction pickup or current probe pickup over bat-
1.
See Figure 1-15. Connect ammeter between negative
tery negative cable.
battery cable and crankcase ground. With this arrange-
ment, you will also pick up any regulator drain.
2.
With ignition key switch turned to OFF and all lights and
x0546x1x
accessories off, observe current reading.
a. Refer to Table 1-4. Add voltage regulator draw to
2
1
appropriate value for TSM/TSSM. If sum is greater
than reading observed on ammeter, draw is within
limits.
b. A higher reading indicates excessive current draw.
Any accessories must be considered and checked
for excessive drain.
NOTE
3
A battery with a surface discharge condition could suffer a
static drain. Correct by cleaning battery case.
1.
12 VDC battery
2.
Battery negative cable
3.
Crankcase
Table 1-4. Maximum Meter Reading
(Averaged)
Figure 1-15. Milliampere Draw Test
(Ignition turned to OFF)
ITEM
DRAW IN MILLIAMPERES
Voltage regulator
0.5
Speedometer
0.5
d0004x8x
Load tester
Tachometer (if equipped)
0.5
TSM (non security models)
0.5
TSSM (disarmed)
3.0
TSSM (armed)
3.0
TSSM (storage mode)
0.5
Security siren
20.0*
* Siren will draw for 2-24 hours from time motorcycle battery is con-
nected and 0.05 milliamperes once siren battery is charged. For
best results, disconnect siren during milliampere draw test.
Figure 1-16. Check Current Draw (Ignition Switch On)
1-18
2006 Sportster: Starting & Charging
HOME
2. Disconnect stator plug from voltage regulator. Start the
USING LOAD TESTER
motorcycle and run the engine at 2000 RPM.
1.
See Figure 1-18. Connect load tester.
3. With ignition and all continuously running lights and
a. Connect negative and positive leads to battery ter-
accessories turned on (headlamp on high beam), read
minals.
the total current draw.
b. Place load tester induction pickup over positive reg-
4. Compare this reading to the reading obtained after per-
ulator cable.
forming the CURRENT AND VOLTAGE OUTPUT TEST.
a. The current output should exceed current draw by
CAUTION
3.5 amps minimum.
b. If output does not meet specifications, there may be
Do not leave any load switch turned on for more than 20
too many accessories for the charging system to
seconds or overheating and tester damage are possible.
handle.
2. Run the engine at 3000 RPM. Increase the load as
5. Reconnect voltage regulator after testing.
required to obtain a constant 13.0 VDC.
3. The current output should be 19-23 amps. Make note of
Current and Voltage Output Test
measurement for use in Total Current Draw Test.
For this test, you may use either the MCR-101 HD
NOTE
ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL
Rider’s habits may require output test at lower RPM.
SYSTEM ANALYZER or a load tester.
4. See Figure 1-18. After removing the load, read the load
USING MCR-101 HD
tester voltage meter.
1. Connect the MCR-101 HD analyzer leads to the vehicle’s
a. If voltage to the battery is not more than 15 VDC,
battery.
voltage output is within specifications. Investigate
2. Follow the instructions in the analyzer’s instruction man-
other possible problems. See Charging System Test
ual to perform a Charging System Test.
1.7 (Part 1 of 2).
See Figure 1-17. The test results will include a decision on
b. If voltage is higher, voltage regulator is not function-
the charging system’s condition and the measured output
ing properly or connections are loose or dirty.
voltage at idle and at 3000 RPM. The analyzer’s printer will
provide you with a printout including one of two possible test
results:
x0547x1x
1
● CHARGING SYSTEM NORMAL-No problem found.
● CHARGING SYSTEM PROBLEM-The analyzer
detected a problem and will display one of the three fol-
lowing results:
4
a. LOW CHARGING VOLTS-the alternator is not sup-
plying sufficient current for the system’s electrical
loads.
b. HIGH CHARGING VOLTS-The voltage output from
the alternator exceeds the normal regulator limits.
c. INVESTIGATE VOLT OUTPUT-The rev voltage is
lower than the idle voltage.
2
3
x0665x1x
5
1. Load tester
CHARGING TEST
2. Battery
PROBLEM
3. Voltage regulator
4. To Maxi-Fuse (DC output)
LOW
CHARGING VOLTS
5. To stator
IDLE:
12.32V
REV:
12.32V
Figure 1-18. Current and Voltage Output Test
REFER TO H-D
SERVICE MANUAL
Figure 1-17. Charging System Test Results-Printout
2006 Sportster: Starting & Charging
1-19
HOME
Stator Check
4. See Figure 1-20. Remove ground lead. Check resistance
across stator sockets.
1. Turn ignition key switch OFF.
5. Test for resistance with ohmmeter set on the RX1 scale.
2. See Figure 1-19. Connect an ohmmeter.
a. Resistance across the stator sockets should be 0.2-
a. Disconnect voltage regulator connector from alter-
0.4 ohms.
nator stator wiring.
b. If the resistance is higher, the stator is damaged and
b. Insert one ohmmeter lead into a stator connector
must be replaced.
socket.
NOTE
c. Attach the other lead to a suitable ground.
Verify that meter reads 0 ohms when probes are shorted
3. Test for continuity with ohmmeter set on the RX1 scale.
together. If not, subtract lowest value from resistance value of
a. A good stator will show no continuity
(∞ ohms)
stator.
across either stator socket.
b. Any other reading indicates a grounded stator which
must be replaced.
10068
1
10069a
1
3
4
3
2
1.
Alternator stator connector [46B]
2
2.
DVOM set to ohms scale
3.
Meter leads to stator connector sockets
Figure 1-20. Check for Stator Resistance
1. Alternator stator connector [46B]
2. DVOM set to ohms scale
3. Positive meter lead to either
stator connector socket
4. Negative meter lead grounded to engine
Figure 1-19. Test for Grounded Stator
1-20
2006 Sportster: Starting & Charging
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