Harley Davidson 2011 Touring Models. Electrical Diagnostic Manual — page 9
STARTER TROUBLESHOOTING
The troubleshooting tables contain detailed procedures to solve
and correct problems. Follow
gnose starting system problems. The
to locate poor connections or components with excessive
voltage drops.
Table 3-3. Starter Does Not Run or Runs at Very Low Speeds
SOLUTION
POSSIBLE CAUSE
SOURCE OF PROBLEM
Charge battery.
Voltage drop due to discharged battery.
Battery
Replace battery.
Short-circuit or open between electrodes.
Clean and retighten.
Poor contact condition of battery ter-
minal(s).
Repair or replace cable(s).
Poor or no connection at either end of the
battery positive or negative cable.
Wiring
Clean, tighten or replace cable(s) as
needed.
Cracked or corroded battery cable ends.
Tighten connections or repair or replace
wire(s).
Open wire(s) or poor connection at
handlebar switch or start relay, especially
relay ground wire (grounds through
TSM/TSSM/HFSM).
Replace switch.
Poor switch contacts or open switch.
Start switch, clutch switch, engine stop
switch or neutral switch
Replace relay.
Open coil winding.
Start relay
Replace relay.
Poor or no continuity at relay points.
Disarm security system inspect for neutral
or clutch circuit issue.
TSM/TSSM/HFSM has disabled start
relay.
Replace solenoid assembly.
Poor contact condition caused by burned
contacts.
Starter solenoid
Replace solenoid assembly.
Windings open or short-circuited.
Replace starter.
Brushes worn below specification.
Starter motor
Replace starter.
Commutator burnt.
Replace starter.
Commutator high mica.
Replace starter.
Field winding grounded.
Replace starter.
Armature winding grounded or short-cir-
cuited.
Replace starter.
Free running current draw out of range.
Replace starter.
Insufficient brush spring tension.
Replace starter clutch assembly.
Starter clutch failure.
Starter clutch
Table 3-4. Starter Spins But Does Not Engage
SOLUTION
POSSIBLE CAUSE
SOURCE OF PROBLEM
Charge battery.
Voltage drop due to discharged battery.
Battery
Replace battery.
Short-circuit or open between electrodes.
Clean and retighten.
Poor contact condition of battery ter-
minal(s).
Replace starter clutch assembly.
Pinion gear teeth worn out.
Starter motor
Replace clutch shell and sprocket.
Excessively worn teeth.
Gear teeth on clutch shell and sprocket.
Replace starter clutch assembly.
Starter clutch failure.
Starter clutch
3-6 2011 Touring Diagnostics: Starting and Charging
Table 3-5. Starter Does Not Stop Running
SOLUTION
POSSIBLE CAUSE
SOURCE OF PROBLEM
Replace start switch or start relay.
Unopened contacts.
Start switch or start relay
Replace start switch or start relay.
Poor return caused by sticky switch or
relay contacts.
Replace starter solenoid assembly.
Coil shorted.
Starter solenoid
Replace starter solenoid assembly.
Contact plate melted and stuck.
STARTER TESTING
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 3-6. Starter Testing Diagnostic Faults
POSSIBLE CAUSES
Short to voltage at starter solenoid
Start switch malfunction
Short to voltage on start relay supply circuit
Start relay malfunction
1. Starting System Operational Test
1.
With IGN ON, transmission in neutral and the engine stop
switch in the RUN position, press the start switch.
2.
Does the starter spin?
a.
Yes. Starter spins, but does not engage. See
3.2 STARTING SYSTEM, Starter Spins But Does Not
Engage
.
b.
Yes. Starter stalls or spins too slowly. See
3.2 STARTING SYSTEM, Starter Stalls or Spins Too
Slowly
.
c.
Yes. Starter runs on.
d.
No.
2. Audible Noise Test
1.
While listening for audible clicking noises from the start
relay and starter solenoid, press the start switch.
2.
Is there a click?
a.
Yes. Start solenoid clicks. See
SYSTEM, Starter Solenoid Clicks
.
b.
Yes. Start relay clicks. See
c.
No. See
3.2 STARTING SYSTEM, Nothing Clicks
.
3. Starter Solenoid Test
1.
Disconnect starter solenoid [128].
2.
Does starter stop?
a.
Yes.
b.
No. Replace starter solenoid assembly. (5845)
4. Start Switch Circuit Test
1.
Turn IGN OFF, remove start relay.
2.
Turn IGN ON. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C) test for voltage at fuse block
[64-1B] socket terminal 4H (BK/R) wire.
3.
Is battery voltage present?
a.
Yes.
b.
No.
5. Start Switch Circuit Short to Voltage Test
1.
Turn IGN OFF, disconnect right hand controls [22].
2.
Turn IGN ON, test for voltage at [22B] terminal 6.
3.
Is voltage present?
a.
Yes. Except FLHR/C.
b.
Yes. FLHR/C. Repair short to voltage between [22B]
terminal 6 and [64-1B] socket terminal 4H (BK/R) wire.
c.
No.
6. Start Switch Circuit Short to Voltage [2B]
Test
1.
Turn IGN OFF, disconnect interconnect harness [2].
2.
Turn IGN ON, test for voltage at [2B] terminal 2.
3.
Is voltage present?
a.
Yes. Repair short to voltage between [2B] terminal 2
and [22B] terminal 6 (BK/R) wire. (5041)
b.
No.
7. Start Switch Circuit Short to Voltage [2A]
Test
1.
Test for voltage at [2A] terminal 2.
2.
Is voltage present?
a.
Yes. Repair short to voltage between [2A] terminal 2
and [64-1B] socket terminal 4H (BK/R) wire. (5041)
b.
No.
8. Start Switch Test
1.
Test for continuity between [22A] terminal 4 (W/BK) wire
and terminal 6 (BK/R) wire.
2011 Touring Diagnostics: Starting and Charging 3-7
2.
Is continuity present?
a.
Yes. Replace start switch. See the service manual.
(5818)
b.
No. Repair short to voltage on [22A] terminal 6 (BK/R)
wire. (5041)
9. Start Relay Test
1.
Perform relay test. See
TROUBLESHOOTING, Relay Diagnostics
2.
Is the start relay good?
a.
Yes. Perform wiggle test to locate short to voltage
between [64-1B] socket terminals 4G (GN) wire or
3H (R/GY) wire. See
. (5041)
b.
No. Replace start relay. (5832)
NOTHING CLICKS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
BREAKOUT BOX
HD-42682
Table 3-7. Nothing Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Open fuse
Open ignition switch feed circuit
Start switch malfunction
Start relay malfunction
TSM/TSSM/HFSM malfunction
Ignition switch malfunction
Open ignition circuit
Open start switch circuit
Neutral switch malfunction
Open neutral circuit
Clutch switch malfunction
Open clutch switch circuit
Engine stop switch malfunction
Open ignition circuit
Open security circuit
NOTE
Verify that vehicle is in neutral and that the key fob is present
and in working order (if security equipped) and that the engine
stop switch is in RUN position.
1. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed, attempt to
start engine, if nothing clicks continue with tests.
2. Fuse Test
1.
Verify that all fuses including main fuse are good.
2.
Are all fuses good?
a.
Yes.
b.
No. Replace fuse and repair circuit accordingly. If
problem is still present, continue with tests.
3. Ignition Circuit Test
1.
With IGN ON, verify that ignition circuit is working properly.
2.
Do lights illuminate?
a.
Yes.
b.
No.
4. Ignition Switch Supply Voltage Test
1.
With IGN OFF, disconnect ignition switch [33].
2.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and multimeter, test for battery voltage at ignition
switch [33B] terminal 2 on all vehicles except for FLHR/C
and terminal B on FLHR/C (R) wire.
3.
Is battery voltage present?
a.
Yes.
b.
No. Except FLHR/C. Repair open between ignition
switch [33B] terminal 2 and main fuse [5B] terminal
B (R) wire. (5041)
c.
No. FLHR/C.
5. Ignition Switch to [222] Test
1.
Disconnect console ignition switch [222].
2.
Test for continuity between ignition switch [33B] terminal
B and [222A] terminal B.
3.
Is continuity present?
a.
Yes. Repair open in (R) wire from [222B] terminal B
and [64-1B] socket terminal 2C.
b.
No. Repair open in (R) wire from [222A] terminal B
and ignition switch [33B] terminals B.
6. Ignition Switch Test
1.
With IGN ON, test for continuity between ignition switch
[33A] terminals B+ and IGN.
3-8 2011 Touring Diagnostics: Starting and Charging
2.
Is continuity present?
a.
Yes. On all vehicles except for FLHR/C, repair open
in (R/BK) wire from [33B] terminal 3. (5041)
b.
No. Except FLHR/C. Replace ignition switch. See
the service manual. (7287)
c.
No. FLHR/C.
7. Ignition Switch to [222] Continuity Test
1.
Test for continuity between ignition switch [33B] terminal
A and [222A] terminal A.
2.
Is continuity present?
a.
Yes. Repair open in (R/BK) wire from [222B] terminal
B and [64-2B] socket terminal 1E.
b.
No. Repair open in (R/BK) wire from [222A] terminal
B and ignition switch [33B] terminals B.
8. Start Switch Circuit Voltage Test
1.
With IGN OFF, remove start relay.
2.
Turn IGN ON.
3.
While pressing the start switch, using HARNESS CON-
NECTOR TEST KIT (Part No. HD-41404-C) and a multi-
meter, test for battery voltage at [64-1B] socket terminal
4H (BK/R) wire.
4.
Is battery voltage present?
a.
Yes.
b.
No.
9. Start Switch Test
1.
Turn IGN OFF and disconnect right hand controls [22].
2.
With the start switch pressed, test for continuity between
[22A] terminals 6 (BK/R) wire and 4 (W/B) wire.
3.
Is continuity present?
a.
Yes.
b.
No. Replace the start switch. See the service manual.
(5818)
10. Start Switch Circuit Continuity Test
1.
Test for continuity between [22B] terminal 6 and [64-1B]
socket terminal 4H (BK/R) wire.
2.
Is continuity present?
a.
Yes.
b.
No. Except FLHR/C.
c.
No. FLHR/C. Repair (BK/R) wire between [22B] ter-
minal 6 and [64-1B] socket terminal 4H.
11. Start Switch Circuit Continuity [2B] Test
1.
Disconnect interconnect harness [2].
2.
Test for continuity between [2B] terminal 2 and [22B] ter-
minal 6.
3.
Is continuity present?
a.
Yes. Repair open between [2B] terminal 2 and [22B]
terminal 6 (BK/R) wire. (5041)
b.
No.
12. Start Switch Circuit Continuity [2A] Test
1.
Test for continuity between [2A] terminal 2 and [64-1B]
socket terminal 4H (BK/R) wire.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open between [2A] terminal 2 and [64-1B]
socket terminal 4H (BK/R) wire. (5041)
13. Start Relay Control Circuit Test
1.
Test for continuity between [64-1B] socket terminal 3G
(TN/GN) wire and ground.
2.
Is continuity present?
a.
Yes. Replace start relay. See the service manual. If
problem is still present, see
. (5832)
b.
No.
14. Start Relay Control Circuit Open Test
1.
Connect BREAKOUT BOX (Part No. HD-42682) between
wire harness [30B] and TSM/TSSM/HFSM [30A]. See
.
2.
Test for continuity between [64-1B] socket terminal 3G
and breakout box terminal 9 (TN/GN) wire.
3.
Is continuity present?
a.
Yes.
b.
No, without anti-theft tracking module. Repair open
between [64-1B] socket terminal 3G and
TSM/TSSM/HFSM [30B] terminal 9 (TN/GN) wire.
(5041)
c.
No, with anti-theft tracking module.
15. TSM/TSSM/HFSM Ground Test
1.
Test for continuity between breakout box terminal 12 (BK)
wire and ground.
2.
Is continuity present?
a.
Yes.
b.
No. Repair open between TSM/TSSM/HFSM [30B]
terminal 12 and right GND 2 (BK/GN) wire. (5041)
16. Continuity at Neutral Switch Test
1.
Verify that transmission is in neutral.
2.
Measure for resistance between breakout box terminal 4
(TN) wire and ground.
3.
Is resistance less than 10 Ohms?
a.
Yes.
b.
No.
2011 Touring Diagnostics: Starting and Charging 3-9
17. Neutral Switch Ground Circuit Test
1.
Test for continuity between neutral switch [131] (BK) wire
and ground.
2.
Is continuity present?
a.
Yes. Replace neutral switch. See the service manual.
(5157)
b.
No. Repair open between neutral switch [131] and
GND 1 (BK) wire. (5041)
18. Start Relay Coil Control Circuit Short to
Voltage Test
1.
Turn IGN ON.
2.
Test for battery voltage on breakout box terminal 9.
3.
Is battery voltage present?
a.
Yes. Repair short to voltage between
TSM/TSSM/HFSM [30B] terminal 9 and [64-1B]
socket terminal 3G on (TN/GN) wire. (5041)
b.
No. Replace TSM/TSSM/HFSM. See the service
manual. (5838)
19. Engine Stop Switch Voltage Test
1.
Test for voltage between [22B] terminal 3 and ground.
2.
Is battery voltage present?
a.
Yes. Replace engine stop switch. See the service
manual.
b.
No. Repair open between ignition fuse and [22B] (GY)
wire.
20. Relay Enable Circuit Continuity Test
1.
Disconnect the anti-theft tracking module.
2.
Test for continuity between [64-1B] socket terminal 3G
and anti-theft tracking module [266B] terminal C (TN/GN)
wire.
3.
Is continuity present?
a.
Yes.
b.
No. Repair open in (TN/GN) wire. (5041)
21. Anti-Theft Tracking Module Test
1.
Test for continuity between breakout box terminal 9 and
anti-theft tracking module [266B] terminal D (TN/GN) wire.
2.
Is continuity present?
a.
Yes. Replace the anti-theft tracking module. See the
service manual. (6756)
b.
No. Repair open in (GN) wire. (5041)
START RELAY CLICKS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Table 3-8. Start Relay Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Starter solenoid malfunction
Open starter solenoid control circuit
Open starter solenoid ground circuit
1. Battery Test
1.
Verify battery condition. See
.
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed, attempt to
start engine, if start relay continues to click and starter
does not engage.
2. Starter Solenoid Control Coil Voltage Test
1.
With IGN OFF, disconnect starter solenoid [128].
2.
Turn IGN ON.
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C) and a multimeter, test for battery voltage on
[128B] terminal 1 (GN) wire.
4.
Is battery voltage present when start switch is pressed?
a.
Yes. Replace starter solenoid assembly. See the
service manual. (5845)
b.
No.
3. Starter Solenoid Control Coil Continuity
Test
1.
Turn IGN OFF and remove start relay.
2.
Test for continuity between [128B] terminal 1 and fuse
block [64-1B] socket terminal 4G (GN) wire.
3.
Is continuity present?
a.
Yes. See
TROUBLESHOOTING, Relay Diagnostics
. If relay
tests good, continue with tests.
b.
No. Repair open between [128B] terminal 1 and [64-
1B] socket terminal 4G (GN) wire. (5041)
4. Start Solenoid Wiring Inspection Test
1.
Inspect for corrosion or damage to the wiring from [128A]
to starter solenoid.
2.
Are there any problems?
a.
Yes. Repair damage or replace starter solenoid
assembly. See the service manual. If problem is still
present, then continue with tests.
(5845)
b.
No.
3-10 2011 Touring Diagnostics: Starting and Charging
5. Starter Solenoid Test
1.
With IGN ON, press the start switch.
2.
Does starter solenoid click?
a.
Yes. See
3.2 STARTING SYSTEM, Starter Solenoid
.
b.
No. Repair open in [64-1B] socket terminal 3H (R/BK)
wire.
STARTER SOLENOID CLICKS
Table 3-9. Starter Solenoid Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Open battery cable
Open starter cable
Mechanical binding
1. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed. Attempt to
start engine. If starter solenoid continues to click and
starter does not engage, then continue with tests.
2. Starter Voltage Drop Test
1.
Perform voltage drop tests from battery (+) to starter stud
on starter (BK) wire. See
2.
Is voltage drop greater than 1.0V?
a.
Yes.
b.
No.
3. Starter Solenoid Voltage Drop Starter Side
Test
1.
Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 2 (BK) wire.
2.
Is voltage drop greater than 1.0V?
a.
Yes.
b.
No. Replace starter solenoid assembly. See the ser-
vice manual. (5845)
4. Starter Solenoid Battery Side Voltage
Drop Test
1.
Perform voltage drop test from battery (+) terminal to
starter solenoid terminal 1 (BK) wire.
2.
Is voltage drop greater than 1.0V?
a.
Yes. Repair or replace (BK) wire from starter solenoid
terminal 1 to battery (+) terminal. (5041)
b.
No. Replace starter solenoid assembly. See the ser-
vice manual. (5845)
5. Starter Ground Circuit Voltage Drop Test
1.
Perform voltage drop test from battery (-) terminal to
ground.
2.
Is voltage drop greater than 1.0V?
a.
Yes. Inspect (BK) wire for damage from battery (-)
terminal to chassis ground, repair or replace if
necessary.
b.
No.
6. Starter Ground Test
1.
Remove starter attaching bolts. See the service manual.
2.
Clean bolts and starter base, install starter bolts.
3.
Does engine crank?
a.
Yes. Engine cranks at normal speed. Repair com-
plete.
b.
Yes. Engine cranks, but at a slower speed. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test
.
c.
No. Replace starter. See the service manual. (5817)
7. Starter Draw Test
1.
Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test
.
2.
Perform Starter Motor Free Running Current Draw Test
(on bench). See
Free Running Current Draw Test
.
3.
Are test results within range?
a.
Yes.
b.
No. Replace starter. See the service manual. (5817)
8. Mechanical Binding Test
1.
Remove spark plugs and place transmission in 5th gear.
2.
Raise vehicle.
3.
Rotate rear wheel.
4.
Check for engine binding in the primary and/or crankshaft
or starter clutch.
5.
Is engine binding? See the service manual.
a.
Yes. Repair as needed. (Use appropriate code).
b.
No. Replace starter solenoid assembly. (5845)
2011 Touring Diagnostics: Starting and Charging 3-11
STARTER SPINS BUT DOES NOT ENGAGE
Table 3-10. Starter Spins But Does Not Engage Diagnostic
Faults
POSSIBLE CAUSES
Clutch assembly
Clutch shell and sprocket
1. Pinion Gear and Clutch Shell Test
1.
Remove primary cover.
2.
Inspect for damage to starter pinion gear and clutch shell
and sprocket.
3.
Is damage present?
a.
Yes. Replace the clutch assembly or clutch shell and
sprocket. See the service manual. (5825)
b.
No. Replace the clutch assembly. See the service
manual. (5837)
STARTER STALLS OR SPINS TOO SLOWLY
Table 3-11. Starter Stalls or Spins Too Slowly Diagnostic
Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Poor connections at starter ground
Open battery cable
Open starter cable
1. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed. If symptom
is still present, then continue with tests.
2. Starter Stud Voltage Drop Test
1.
Perform voltage drop test from battery (+) terminal to
starter stud on starter (BK) wire. See
AND TROUBLESHOOTING, Voltage Drop
2.
Is voltage drop greater than 1.0V?
a.
Yes.
b.
No.
3. Starter Ground Circuit Voltage Drop Test
1.
Perform voltage drop test between battery (-) terminal and
starter attaching bolts.
2.
Is voltage drop greater than 1.0V?
a.
Yes. Clean ground connections. (5041)
b.
No.
4. Starter Draw Test
1.
Perform Starter Current Draw Test on motorcycle. See
3.3 TESTING STARTER ON MOTORCYCLE, Starter
Current Draw Test
.
2.
Perform Starter Motor Free Running Current Draw Test
(on bench). See
Free Running Current Draw Test
.
3.
Are test results within range?
a.
Yes. With the spark plugs removed and the transmis-
sion in 5th gear, rotate rear wheel. Check for engine,
primary and/or crankshaft bind. (Use appropriate
code)
b.
No. Replace starter. See the service manual. (5817)
5. Starter Solenoid Voltage Drop Starter Side
Test
1.
Perform voltage drop test between battery (+) terminal to
starter solenoid terminal 2.
2.
Is voltage drop greater than 1.0V?
a.
Yes.
b.
No. Repair connection or (BK) wire between starter
solenoid and starter. (5041)
6. Starter Solenoid Battery Side Voltage
Drop Test
1.
Perform voltage drop test between battery (+) terminal
and starter solenoid terminal 1 (R) wire.
2.
Is voltage drop greater than 1.0V?
a.
Yes. Repair or replace connection between battery
(+) terminal and starter solenoid terminal 1 (R) wire.
(5041)
b.
No. Repair or replace starter solenoid assembly. See
the service manual. (5845)
3-12 2011 Touring Diagnostics: Starting and Charging
3.3
TESTING STARTER ON MOTORCYCLE
STARTER CURRENT DRAW TEST
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
NOTES
•
Engine temperature should be stable and at room temper-
ature.
•
Battery should be fully charged.
Check starter current draw with an induction ammeter before
disconnecting battery. Proceed as follows:
1.
Verify that transmission is in neutral and engine stop switch
is in OFF position.
2.
Remove start relay.
3.
Using HARNESS CONNECTOR TEST KIT (Part No. HD-
41404-C), connect patch cord to fuse block [64-1B] socket
terminals 4G and 3H.
4.
Clamp induction ammeter over positive starter cable to
starter solenoid.
NOTE
In next step with engine stop switch in OFF position and purple
male probes connected to the [64-1B] terminals 4G and 3H in
place of the start relay, starter will turn but engine will not start.
This configuration also prevents diagnostic trouble codes from
being set.
5.
With IGN ON, read the ammeter. Disregard initial high
current reading which is normal when engine is first turned
over.
a.
Typical starter current draw will range between 160-
200A.
b.
If starter current draw exceeds 250A, then the
problem may be in the starter or starter drive. See
3.4 TESTING STARTER ON BENCH, Free Running
Current Draw Test
.
2011 Touring Diagnostics: Starting and Charging 3-13
3.4
TESTING STARTER ON BENCH
FREE RUNNING CURRENT DRAW TEST
1.
Place starter in vise, using a clean shop towel to prevent
scratches or other damage.
2.
. Attach one heavy jumper cable (6 gauge
minimum).
a.
Connect one end to the starter mounting flange.
b.
Connect the other end to the battery (-) terminal of a
fully charged battery.
3.
Connect a second heavy jumper cable (6 gauge minimum).
a.
Connect one end to the battery (+) terminal of the
battery.
b.
Connect the other end to the battery terminal on the
starter. Place an induction ammeter over cable.
Keep fingers and clothing away from starter gear to pre-
vent personal injury. (00613b)
4.
Connect a smaller jumper cable (14 gauge minimum).
a.
Connect one end to the positive (+) terminal of the
battery.
b.
Connect the other end to the solenoid relay terminal.
5.
Check ammeter reading.
a.
Ammeter should show 90A max.
b.
If reading is higher, replace starter. See the service
manual.
c.
If starter current draw on vehicle was over 120A and
this test was within specification, there may be a
problem with engine or primary drive.
2
3
4
5
1
ed02865
1.
Mounting flange
2.
Battery
3.
Induction ammeter
4.
Battery terminal
5.
Relay terminal
Figure 3-5. Free Running Current Draw Test
STARTER SOLENOID
Do not disassemble solenoid. Before testing, disconnect field
wire from solenoid motor terminal as shown in
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
1.
. Using a 12V battery, connect three sep-
arate 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
solenoid assembly.
1
2
3
4
ed02866
1.
Battery
2.
Solenoid housing
3.
Solenoid relay terminal
4.
Solenoid motor terminal
Figure 3-6. Pull-In Test
SOLENOID HOLD-IN TEST
1.
See
. With test leads still connected in the
manner specified in the previous
ON BENCH, Solenoid Pull-In Test
motor terminal/battery negative test lead at negative bat-
tery post only; reconnect loose end of this test lead to
positive battery post instead.
3-14 2011 Touring Diagnostics: Starting and Charging
2.
Observe starter shaft.
a.
If starter shaft remains extended, solenoid is working
properly.
b.
If starter shaft retracts, replace solenoid assembly.
1
2
3
4
ed02867
1.
Battery
2.
Solenoid housing
3.
Solenoid relay terminal
4.
Solenoid motor terminal
Figure 3-7. Hold-In Test
SOLENOID RETURN TEST
1.
. With test leads still connected in the
manner specified at the end of
ON BENCH, Solenoid Hold-In Test
relay terminal/positive battery post test lead at either end.
2.
Observe starter pinion.
a.
If starter shaft retracts, solenoid is working properly.
b.
If starter shaft does not retract, replace solenoid
assembly.
1
2
3
4
ed02868
1.
Battery
2.
Solenoid housing
3.
Solenoid relay terminal
4.
Solenoid motor terminal
Figure 3-8. Return Test
2011 Touring Diagnostics: Starting and Charging 3-15
3.5
CHARGING SYSTEM
DESCRIPTION AND OPERATION
The charging system is the source of electric current that sup-
plies power to run the ignition, lights, accessories and charge
the battery. AC voltage is generated by an alternator assembly
driven by the crankshaft. A rotor supplied with a magnetic field
spins around a stator. A rectifier (located in the regulator)
converts the voltage from AC to DC. A regulator ensures that
the output voltage is properly matched to the battery voltage
as engine speed varies. Even though the alternator provides
additional voltage at all engine speeds, it is not recommended
to idle the vehicle for long periods of time.
Alternator
The alternator consists of two main components:
•
The rotor which mounts to the primary side of the crank-
shaft.
•
The stator which is attached to the crankcase half.
Voltage Regulator
. The voltage regulator is a series regulator.
The circuit combines the functions of rectifying and regulating.
TROUBLESHOOTING
When the charging system fails to charge or does not charge
at a satisfactory rate, check the following items.
Battery
Test for a weak or dead battery. Battery must be fully charged
in order to perform a load test or starting or charging tests. See
Wiring
The stator connections must be clean and tight.
Check for corroded or loose connections in the charging system
circuit.
Voltage Regulator Inspection
The voltage regulator must have clean, tight connections for
proper operation. Verify both AC and DC connectors are fully
inserted and locked with the regulator latch.
Job/Time Code Values
Dealership Technicians filing warranty claims should use the
job/time code values printed in bold text next to the appropriate
repair.
Connector Information
For additional information about the connectors in the following
diagram(s) and diagnostic procedure(s), including the color of
the harness test kit terminal probes, see
Stator
Main Fuse
40A
Starter
Battery
Red
Band
Battery
Ground
Left
GND1
(Dirty)
-
+
DC
AC
B
A
+
-
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
BK
R
R
R
[77A]
[77B]
[47B]
[47A]
[5B]
em00692
Figure 3-9. Charging System Circuit
3-16 2011 Touring Diagnostics: Starting and Charging
LOW OR NO CHARGING
Table 3-12. Low or No Charging Diagnostic Faults
POSSIBLE CAUSES
Low battery
Stator malfunction
Rotor malfunction
Voltage regulator malfunction
Open voltage regulator circuit
Stator shorted to ground
AC wire shorted to ground
1. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed. Verify
repair.
NOTE
A discharged battery may show a reading under 13V even
though the charging system is working properly.
2. Off Idle Voltage Test
1.
With the vehicle is neutral, start engine and run at 3000
rpm.
2.
Test battery voltage.
3.
Is voltage above 13V?
a.
Yes. Charging system working properly.
b.
No.
3. AC Output Test
1.
Perform an AC output test. See
2.
Did the output test pass?
a.
Yes.
b.
No.
4. Stator Test
1.
Perform a stator test. See
2.
Is the stator good?
a.
Yes.
b.
No. Replace stator. See the service manual. (5309)
5. Rotor Inspection Test
1.
Inspect the rotor for damage.
2.
Remove center bolt and inspect for signs of the center
hole becoming oval. See the service manual.
3.
Verify that stator bolts have not backed out and contacted
the rotor.
4.
Is rotor in good condition?
a.
Yes.
b.
No. Replace rotor. See the service manual. (5319)
6. Voltage Regulator Power Circuit Test
1.
With IGN OFF, disconnect voltage regulator [77].
2.
Test for continuity between voltage regulator [77B] terminal
+ and main fuse [5B].
3.
Is continuity present?
a.
Yes.
b.
No. Repair open wire between voltage regulator [77B]
terminal + and [5B]. (5041)
7. Voltage Regulator Ground Circuit Test
NOTE
The voltage regulator ground must have a clean, tight connec-
tion for proper grounding.
1.
Test for continuity between voltage regulator [77B] terminal
- and ground.
2.
Is continuity present?
a.
Yes. Replace voltage regulator. See the service
manual. (5316)
b.
No. Repair open wire between voltage regulator [77B]
terminal - and GND 1 (BK) wire. (5041)
OVERCHARGING
Table 3-13. Overcharging Diagnostic Faults
POSSIBLE CAUSES
Voltage regulator malfunction
1. Battery Voltage Test
1.
With the vehicle in neutral, start engine and run at 3000
rpm, test battery voltage.
2.
Is voltage above 15.5V?
a.
Yes.
b.
No. Charging system working properly.
2. Voltage Regulator Ground Circuit Test
NOTE
The voltage regulator ground must have a clean, tight connec-
tion for proper grounding.
1.
With IGN OFF, disconnect voltage regulator [77].
2.
Test for continuity between voltage regulator [77B] terminal
- and ground.
2011 Touring Diagnostics: Starting and Charging 3-17
3.
Is continuity present?
a.
Yes. Replace voltage regulator. See the service
manual. (5316)
b.
No. Repair open wire between voltage regulator [77B]
terminal - and GND 1 (BK) wire. (5041)
LOW BATTERY AFTER EXTENDED IGN OFF
Table 3-14. Low Battery After Extended IGN OFF
Diagnostic Faults
POSSIBLE CAUSES
Battery
Accessories improperly wired to stay on at all times
Excessive draw from electrical component with IGN OFF
Battery self-discharge and/or component draw because
motorcycle was not operated for a long period
1. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes.
b.
No. Charge or replace battery as needed. Verify
repair.
2. Amp Draw Test
1.
Perform a milliampere draw test. See
SYSTEM, Battery Charging Tests
2.
Did the test exceed maximum draw?
a.
Yes. Repair excessive draw and run test again. (5308)
b.
No. System is working properly.
BATTERY RUNS DOWN DURING USE
Table 3-15. Battery Runs Down During Use Diagnostic
Faults
POSSIBLE CAUSES
Low battery
Excessive accessory draw
Accessories on when idling or low rpm riding for extended
period
1. Total Current Draw Test
1.
Perform a Total Current Draw and Output Test. See
3.5 CHARGING SYSTEM, Battery Charging Tests
2.
Does charging system exceed current draw by 3.5A?
a.
Yes.
b.
No. System accessory power requirements exceed
charging system capability.
2. Battery Test
1.
Verify battery condition. See
2.
Is battery condition good?
a.
Yes. System is working properly.
b.
No. Charge or replace battery as needed.
BATTERY CHARGING TESTS
TOOL NAME
PART NUMBER
HARNESS CONNECTOR TEST KIT
HD-41404-C
Milliampere Draw Test
NOTE
Be sure accessories are not wired so they stay on at all times.
This condition could drain battery completely if vehicle is parked
for a long time. Test for this by connecting ammeter between
negative battery terminal and battery.
1.
If vehicle is equipped with HFSM, enable service mode
before performing test.
2.
Disconnect the security siren (if equipped).
3.
Remove main fuse.
NOTE
With IGN OFF, an initial current draw of up to 200 mA will occur
directly after connecting meter. This should drop to the values
shown in
in less than one minute.
4.
. Using HARNESS CONNECTOR TEST
KIT (Part No. HD-41404-C), connect ammeter to main
fuse socket terminals. With this arrangement, you will pick
up any drain.
5.
With IGN OFF and all lights and accessories off, observe
current reading.
a.
Add voltage regulator draw to appropriate value for
TSM/TSSM/HFSM and ECM. If observed ammeter
reading is less than listed in table, draw is within limits.
Refer to
b.
A higher reading indicates excessive current draw.
Any accessories must be considered and checked
for excessive drain.
3-18 2011 Touring Diagnostics: Starting and Charging
Table 3-16. Milliampere Draw Test
MAXIMUM DRAW
IN MILLIAMPERES
ITEM
1.0
ECM
1.0
Speedometer
1.0
Tachometer
1.0
TSM (no security)
3.0
TSSM (armed)
3.0
TSSM (disarmed)
1.0
TSSM (storage mode)
1.0
HFSM
20.0*
Security siren (optional)
2.0
Voltage regulator
2.0
Radio
1.0
High output amplifier
1.0
CB module
1.0
XM module
* Siren draws for 2-24 hours from the time the motorcycle
battery is connected and 0.05 milliamperes once siren battery
is charged. Disconnect siren during milliampere draw test.
BK
BK
BK
BK
BK
Left
GND1
(Dirty)
Stator
1 2 3
1 2 3
- +
- +
B
A
R
R
R
R
1
2
3
[5B]
[77A]
[77B]
[47B]
[47A]
em00693
1.
Ammeter
2.
Main fuse socket
3.
Voltage regulator
Figure 3-10. Milliampere Draw Test (Ignition Turned to
OFF)
Total Current Draw and Output Test
If battery runs down during use, the current draw of the
motorcycle components and accessories may exceed output
of the charging system.
NOTE
If a load tester is unavailable, an ammeter with current probe
may be used.
Turn battery load tester OFF before connecting tester
cables to battery terminals. Connecting tester cables with
load tester ON can cause a spark and battery explosion,
which could result in death or serious injury. (00252a)
1.
See
. Connect load tester.
a.
Connect negative and positive leads to battery ter-
minals.
b.
Place load tester induction pickup over battery neg-
ative cable.
2.
With IGN OFF, disconnect voltage regulator [77].
3.
Start engine.
4.
Turn all continuously running lights and accessories turned
ON (headlamp on high beam).
5.
Run engine at 3000 rpm, and make note of the current
draw.
6.
Turn engine OFF.
7.
With IGN OFF, connect voltage regulator [77].
8.
Remove the induction pickup from the battery negative
cable.
9.
Place induction pickup over positive regulator cable.
10. Start engine and run at 3000 rpm.
NOTE
Do not leave any load switch turned on for more than 20
seconds or overheating and tester damage are possible.
11. Increase the load as required to obtain a constant 13.0V.
12. Current output should be 35-50A. Make note of current
output.
NOTE
Rider's habits may require output test at lower rpm.
13. Compare both of these readings.
a.
The current output should exceed current draw by
3.5A minimum.
b.
If output does not meet specifications, there may be
too many accessories for the charging system to
handle.
2011 Touring Diagnostics: Starting and Charging 3-19
1
2
3
ed02802
1.
Load tester
2.
Induction pickup
3.
Battery
Figure 3-11. Check Current Draw (Ignition Switch On)
Stator Test
1.
Turn IGN OFF.
2.
. Connect an ohmmeter.
a.
Disconnect voltage regulator [47] from stator wiring.
b.
Insert one ohmmeter lead into a stator connector
socket.
c.
Attach the other lead to a suitable ground.
3.
Test for continuity.
a.
A good stator will show no continuity (open circuit)
between all stator sockets and ground.
b.
Any other reading indicates a grounded stator which
must be replaced.
4.
See
. Remove ground lead. Measure resist-
ance across stator [47B] terminals 1-2, 2-3 and 3-1.
a.
Resistance across all the stator terminals should be
0.1-0.3 Ohm.
b.
If the resistance is higher, the stator is damaged and
must be replaced.
c.
If resistance is lower, the stator may have a turn-to-
turn short and should be replaced.
NOTE
When measuring resistance (Ohms), compensate for test lead
resistance before performing the measurement. Select the
Ohms position and touch the test leads together. Refer to the
multimeter user's manual to either zero the display or manually
subtract the test lead resistance from the measured circuit's
value.
ed02027
Figure 3-12. Test for Grounded Stator (Typical)
ed02028
Figure 3-13. Check for Stator Resistance (Typical)
3-20 2011 Touring Diagnostics: Starting and Charging
AC Output Test
1.
. Test AC output.
a.
Disconnect voltage regulator [47] from alternator
stator wiring.
b.
Test for VAC across stator [47B] terminals 1 to 2.
c.
Run the engine at 2000 rpm. The VAC output should
be 32-46 VAC (approximately 16-22 per 1000 rpm).
d.
Repeat test using terminals 2 to 3 and 1 to 3.
2.
Compare test results to specifications.
a.
If the output is below specifications, charging problem
could be a faulty rotor or stator.
b.
If output is within specifications, charging problem
might be faulty voltage regulator. Replace as required.
See the service manual.
3.
Check the output again as previously described under
Total Current Draw and Output Test.
ed02029
Figure 3-14. Check Stator AC Voltage Output (Typical)
2011 Touring Diagnostics: Starting and Charging 3-21
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