Harley Davidson 2008 Sportster Models. Electrical Diagnostics Manual — page 2

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

Continued from

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

Vehicle in neutral. Install breakout box

HD-42682. Measure continuity to ground

on terminal “4” (Gray) (neutral switch).

Is continuity (less than 10 ohms) present?

YES

Clutch Disengaged (pulled in). Measure continuity to

Measure continuity to ground at

ground on terminal “10” (Gray) (clutch switch)

black female terminal at neutral

with clutch disengaged. Is continuity present?

switch. Is continuity present?

YES

Locate and repair open on

Replace neutral switch.

black wire between neutral

5157

switch and ground.

5862

YES

Check for voltage on TSM/

Measure continuity to ground on

TSSM/HSFM terminal “9” (Gray)

terminal “8” on connector [24B].

with key ON. Voltage present?

Is continuity present?

YES

Replace clutch switch.

Locate and repair open

Locate and repair

Replace TSM/TSSM/

on black wire between

5168

short to voltage.

HFSM. See Service

clutch switch and

Manual.

ground.

5830

5838

5861

fc01004_en

2008 Sportster Diagnostics: Starting / Charging 1-9

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

Replace damaged idler

Starter clutch failure.

gear and armature.

Replace starter clutch.

5825

5837

fc01005_en

1-10 2008 Sportster Diagnostics: Starting / Charging

Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery

positive to starter motor terminal. Crank engine.

Is voltage drop greater than 1.0 volt?

YES

Perform voltage drop tests between battery

positive to starter battery terminal. Crank engine.

negative and starter studs or bolts.

Is voltage drop greater than 1.0 volt?

YES

Perform starter motor current

Repair connection

Repair or replace

draw test (on vehicle).

Clean ground

between battery

solenoid

connections.

and starter.

(contacts).

Perform starter motor free

5824

5845

5835

running current draw bench test.

Are test results within range?

YES

Remove spark plugs. While in

5th gear, rotate rear wheel.

Replace or repair

Check for engine, primary

starter motor.

and/or crankshaft bind.

5817

Use appropriate code

fc01006_en

2008 Sportster Diagnostics: Starting / Charging 1-11

STARTER ACTIVATION CIRCUITS

1.3

STARTER ACTIVATION CIRCUITS

ed02788

ITEM A

ITEM B

0.1A

IDEAL CLOSED

CIRCUIT

20A

VDC

200A

ITEM C

ITEM D

0.1A

OPEN CIRCUIT

0.1A

GROUND CIRCUIT

20A

VDC

12V

20A

VDC

200A

1. Start switch

2. Relay

3. Solenoid

4. Starter

5. Battery

6. MAXIFUSE

7. Ignition switch

8. Ignition fuse

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

1-12 2008 Sportster Diagnostics: Starting / Charging

DIAGNOSTICS/TROUBLESHOOTING

1.4

until the source of the potential difference is found. The

VOLTAGE DROP

benefits of doing it this way are speed and accuracy.

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

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

between the source and destination.

b. Readings show the actual voltage dropped, not just

The voltage drop test measures the difference in potential or

the presence of voltage.

the actual voltage dropped between the source and destination.

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

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

is more accurate and will display hard to find poor

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

connections.

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

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

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

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

the final destination or component in the circuit (solenoid

negative (the destination or component).

terminal from relay).

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

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

meter will read the voltage dropped or the difference in

can be checked as well.

potential between the source and destination. An ideal

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

circuit's voltage drop would be

0 volt or no voltage

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

dropped, meaning no difference in potential.

there is nothing more negative than the negative post

of the battery.

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

volts, displaying all the voltage dropped, and the entire

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

difference in potential displayed on the meter.

check.

NOTE

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

Open circuits on the ground side will read zero.

potential difference or voltage dropped on the neg-

ative or ground circuit. This technique is very effective

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

for identifying poor grounds due to powdered paint.

voltage drop is greater, back track through the connections

Even the slightest connection may cause an ohm-

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

cient current is passed through, the resistance caused

by the powdered paint will cause a voltage drop or

potential difference in the ground circuit.

2008 Sportster Diagnostics: Starting / Charging 1-13

TESTING STARTER ON MOTORCYCLE

1.5

START RELAY TEST

ed02791

Open left side cover.

See Figure 1-4. Locate start relay (1) in relay/fuse block

(2) forward of battery (3) on motorcycle's left side.

If replacing old start relay:

a. To unplug old relay, grasp body of relay and with a

gentle rocking motion, pull straight out from relay/

fuse block.

b. To plug in new relay, line up spade terminals of relay

with sockets in relay/fuse block and push relay firmly

into sockets.

The start relay can be tested using the motorcycle's 12

volt battery and a multimeter.

a. See Figure 1-4. Unplug start relay (1) from relay/ fuse

1. Ohmmeter

block (2).

2. Battery

3. Start relay

b. See Figure 1-5. To energize the relay, connect the

negative battery terminal to the relay terminal "85" or

Figure 1-5. Start Relay Test

"2" and relay terminal "86" or "1" to the positive battery

terminal.

STARTER CURRENT DRAW TEST

c. Check for continuity between relay terminals "3" and

"5". A good relay shows continuity (continuity tester

NOTES

lamp "on" or a zero ohm reading on the ohmmeter).

•

Engine temperature should be stable and at room temper-

A malfunctioning relay will not show continuity and

ature.

must be replaced.

•

Battery should be fully charged.

If start relay is functioning properly, plug it into relay/ fuse

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

block and proceed to

1.5 TESTING STARTER ON

ammeter before disconnecting battery. Proceed as follows:

MOTORCYCLE, Starter Current Draw Test.

1. Verify that transmission is in neutral. Disconnect spark

plug wires from spark plug terminals.

ed02790

2. Clamp induction ammeter over positive battery cable next

to starter.

3. With Ignition Switch ON, turn engine over by pressing

starter switch while reading the ammeter. Disregard initial

high current reading which is normal when engine is first

turned over.

a. Typical starter current draw will range from 160 to

200 amperes.

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 Service Manual.

NOTE

1. Start relay

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

2. Relay/fuse blocks

not available.

3. Battery

4. MAXIFUSE

Figure 1-4. Start Relay

1-14 2008 Sportster Diagnostics: Starting / Charging

ed02792

1. Induction ammeter

2. Battery

Figure 1-6. Starter Current Draw Test

2008 Sportster Diagnostics: Starting / Charging 1-15

TESTING STARTER ON BENCH

1.6

FREE RUNNING CURRENT DRAW TEST

ed02794

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

scratches or other damage.

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).

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

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

battery (2).

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

the starter solenoid. Place an induction ammeter (3)

over cable.

1. Mounting flange

2. Battery

Connect a smaller jumper cable (14 gauge minimum).

3. Induction ammeter

4. Battery terminal

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

5. Relay terminal

battery (2).

Figure 1-8. Free Running Current Draw Test

b. Connect the other end to the solenoid relay terminal

(5).

Check ammeter reading.

STARTER SOLENOID

a. Ammeter should show 90 amps maximum.

Do not disassemble solenoid. Before testing, disconnect field

wire from motor terminal as shown in Figure 1-9.

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

See the Service Manual.

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

damage to solenoid.

c. If starter current draw on vehicle was over 200 amps

and this test was within specification, there may be a

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

problem with engine, primary drive or jackshaft.

formed together in one continuous operation. Conduct all three

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

tion.

ed02793

SOLENOID PULL-IN TEST

1. See Figure 1-9. Using a 12 volt battery, connect three

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. Starter motor

2. Nut with washer (metric)

3. Positive battery cable ring terminal

4. Solenoid wire connector [128]

Figure 1-7. Starter Wires

1-16 2008 Sportster Diagnostics: Starting / Charging

ed02795

ed02796

1. Motor terminal

2. Relay terminal

3. Battery

Figure 1-9. Pull-In Test

Figure 1-10. Hold-In Test

SOLENOID HOLD-IN TEST

SOLENOID RETURN TEST

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

1. See Figure 1-11. With test leads still connected in the

manner specified in the previous 1.6 TESTING STARTER

manner specified at the end of the previous 1.6 TESTING

ON BENCH, Solenoid Pull-In Test, disconnect solenoid

STARTER ON BENCH, Solenoid Hold-In Test, disconnect

motor terminal/battery negative test lead at negative bat-

solenoid relay terminal/positive battery post test lead at

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

either end.

positive battery post instead.

2. Observe starter pinion.

2. Observe starter shaft.

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

a. If starter shaft remains extended, solenoid is working

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

properly.

b. If starter shaft retracts, replace the solenoid.

ed02797

1. Motor terminal

2. Relay terminal

3. Battery

Figure 1-11. Return Test

2008 Sportster Diagnostics: Starting / Charging 1-17

CHARGING SYSTEM

1.7

GENERAL

Battery

The charging system consists of the alternator and regulator.

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

The charging system circuit is shown in Figure 1-14.

for battery testing procedures. Battery must be fully charged

in order to perform a load test, or starting or charging tests.

Alternator

However, a partially discharged battery may be tested using

The alternator consists of two main components:

the BATTERY TEST function of the ELECTRICAL SYSTEM

TESTER (Part No. HD-48053).

•

The rotor which mounts to the engine sprocket shaft.

Wiring

•

The stator which bolts to the engine crankcase.

See Figure 1-13. The stator connector plug and socket connec-

Voltage Regulator

tion must be clean and tight.

See Figure 1-12. The voltage regulator (1) is a series regulator

Check for corroded or loose connections in the charging circuit.

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

See Figure 1-14.

fying and regulating.

ed02799

ed02798

1. Voltage regulator

2. DC output connector [77]

Figure 1-12. Voltage Regulator

TROUBLESHOOTING

PART NUMBER

TOOL NAME

Figure 1-13. Stator Connector [46]

HD-48053

ELECTRICAL SYSTEM TESTER

When the charging system fails to charge or does not charge

at a satisfactory rate, make the following recommended checks.

1-18 2008 Sportster Diagnostics: Starting / Charging

em01119

Battery

Stator

30 Amp

MAXIFUSE

[5]

B A

Voltage

Regulator

[46B]

[46A]

Powertrain

Ground

Point

[GND1]

[77B] [77A]

Pin Connector

(A side)

Socket Connector

(B side)

Figure 1-14. Charging System Circuit

2008 Sportster Diagnostics: Starting / Charging 1-19

Charging System (Part 1 of 2)

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

fc01060_en

System (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.

1-20 2008 Sportster Diagnostics: Starting / Charging

Charging System (Part 2 of 2)

Continued From

Charging System (Part 1 of 2).

Perform CURRENT OUTPUT TEST. Record

measurement and compare with TOTAL

CURRENT

DRAW TEST before proceeding.

PASS

FAIL

Perform

VOLTAGE

STATOR CHECK.

OUTPUT TEST.

PASS

FAIL

PASS

FAIL

Replace

Perform AC

Replace

System tests good up to this point.

voltage regulator.

OUTPUT TEST.

stator.

Suspect:

5316

5312

• Accessories on for long periods when

vehicle is parked and not running.

PASS

FAIL

• Accessories on when vehicle is

ridden very slowly for long periods.

Replace voltage

• Battery self-discharge and/or

regulator.

Inspect rotor.

Perform CURRENT

accessory draw because vehicle was

OUTPUT TEST.

not operated for a long period.

5315

ASS

FAIL

ASS

FAIL

System

Damaged or

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.

fc01061_en

2008 Sportster Diagnostics: Starting / Charging 1-21

TESTING

ed02801

PART NUMBER

TOOL NAME

HD-48053

ADVANCED BATTERY CONDUCT-

ANCE AND ELECTRICAL SYSTEM

ANALYZER

Milliampere Draw Test

NOTES

•

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

times. This condition could drain battery completely if

vehicle is parked for a long time. Check for this by con-

necting ammeter between negative battery cable and

ground.

•

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

12 VDC battery

seconds after ignition is turned off. Any disruption and

Battery negative cable

reconnection of battery power, such as disconnecting the

Crankcase

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

Figure 1-15. Milliampere Draw Test (Ignition turned to OFF)

HFSM to draw 16-25 mA for 30 seconds.

1. See Figure 1-15. Connect ammeter between negative

battery cable and crankcase ground. With this arrange-

Total Current Draw Test

ment, you will also pick up any regulator drain.

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

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

motorcycle components and accessories may exceed output

accessories off, observe current reading.

of the charging system.

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

NOTE

appropriate value for TSM/TSSM/HFSM. If sum is

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

greater than reading observed on ammeter, draw is

may be used.

within limits.

b. A higher reading indicates excessive current draw.

Any accessories must be considered and checked

for excessive drain.

Turn battery load tester OFF before connecting tester

cables to battery terminals. Connecting tester cables with

NOTE

load tester ON can cause a spark and battery explosion,

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

A battery with a surface discharge condition could suffer a

static drain. Correct by cleaning battery case.

1. See Figure 1-16. To check for this condition, place load

tester induction pickup or current probe pickup over battery

Table 1-4. Maximum Meter Reading (Averaged)

negative cable.

ITEM

DRAW IN MILLIAMPERES

2. Disconnect stator plug from voltage regulator. Start the

motorcycle and run the engine at 2000 RPM.

Voltage regulator

3. With ignition and all continuously running lights and

Speedometer

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

Tachometer (if equipped)

total current draw.

TSM (non-security models)

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

TSSM (disarmed)

forming the CURRENT AND VOLTAGE OUTPUT TEST.

TSSM (armed)

a. The current output should exceed current draw by

3.5 amps minimum.

TSSM (storage mode)

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

HFSM

too many accessories for the charging system to

Security siren

20.0*

handle.

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

5. Reconnect voltage regulator after testing.

is connected and 0.05 milliamperes once siren battery is

charged. For best results, disconnect siren during milliampere

draw test.

1-22 2008 Sportster Diagnostics: Starting / Charging

ed02802

ed02804

1. Load tester

Figure 1-17. Charging System Test Results Printout

2. Induction pickup

3. Battery

Figure 1-16. Check Current Draw (Ignition Switch On)

Current and Voltage Output Test: Using

Load Tester

1. See Figure 1-18. Connect load tester.

Current and Voltage Output Test: Using

a. Connect negative and positive leads to battery ter-

HD-48053

minals.

1. Connect the ADVANCED BATTERY CONDUCTANCE

AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-

b. Place load tester induction pickup over positive regu-

48053) leads to the vehicle's battery.

lator cable.

2. Follow the instructions in the analyzer's instruction manual

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

to perform a Charging System Test.

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

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

See Figure 1-17. The test results will include a decision on the

heating and tester damage can occur.

charging system's condition and the measured output voltage

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

3. The current output should be 28-34 amps. Make note of

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

measurement for use in Total Current Draw Test.

•

CHARGING SYSTEM NORMAL - No problem found.

NOTE

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

•

CHARGING SYSTEM PROBLEM - The analyzer detected

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

4. See Figure 1-18. After removing the load, read the load

ults:

tester voltage meter.

1. LOW CHARGING VOLTS - The alternator is not supplying

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

sufficient current for the system's electrical loads.

voltage output is within specifications. Investigate

other possible problems.

2. HIGH CHARGING VOLTS - The voltage output from the

alternator exceeds the normal regulator limits.

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

properly or connections are loose or dirty.

3. INVESTIGATE VOLT OUTPUT - The rev voltage is lower

than the idle voltage.

2008 Sportster Diagnostics: Starting / Charging 1-23

ed02803

ed02805

1. Load tester

2. Battery

3. Voltage regulator

4. To MAXIFUSE (DC output)

5. To stator

Figure 1-18. Current and Voltage Output Test

Alternator stator connector [46B]

Stator Check

DVOM set to ohms scale

Positive meter lead to either stator connector

1. Turn ignition switch OFF.

socket

2. Connect an ohmmeter.

Negative meter lead grounded to engine

a. Open latch and separate socket connector from pin

Figure 1-19. Test for Grounded Stator

connector.

b. See Figure 1-19. Insert one ohmmeter lead into a

stator connector (1) socket.

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

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

(2).

a. A good stator will show no continuity between either

stator socket and ground.

b. Any other reading indicates a grounded stator which

must be replaced.

4. See Figure 1-20. Remove ground lead. Check resistance

across stator sockets.

5. Test for resistance with ohmmeter set on the RX1 scale.

a. Resistance across the stator sockets should be 0.1-

0.3 ohms.

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

must be replaced.

NOTE

Verify that meter reads 0 ohms when probes are shorted

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

stator.

1-24 2008 Sportster Diagnostics: Starting / Charging

2. Compare test results to specifications.

ed02809

a. If the output is below specifications, charging problem

could be a faulty rotor or stator.

b. If output is good, charging problem might be faulty

voltage regulator. Replace as required.

3. Check the output again as previously described under

CURRENT AND VOLTAGE OUTPUT TEST.

ed02810

1. Alternator stator connector [46B]

2. DVOM set to ohms scale

3. Meter leads to stator connector sockets

Figure 1-20. Check for Stator Resistance

AC Output Check

1. See Figure 1-21. Test AC output.

a. Disconnect voltage regulator connector from alternator

1. Alternator stator connector [46B]

stator wiring.

2. DVOM set to AC volts scale

b. Connect an AC voltmeter across both stator connector

3. Meter leads to stator connector sockets

sockets.

Figure 1-21. Check Stator AC Voltage Output

c. Run the engine at 2000 RPM. The AC output should

be 40-56 volts AC (approximately 20-28 volts AC per

1000 RPM).

2008 Sportster Diagnostics: Starting / Charging 1-25

BATTERY TESTING

1.8

See Figure 1-22. The analyzer printer will provide you with a

GENERAL

printout including one of five possible test results:

Three different procedures may be performed to provide a

•

GOOD BATTERY - Return the battery to service.

good indicator of battery condition: a voltage test, a conduct-

ance test, or a load test.

•

GOOD-RECHARGE - Fully charge the battery and return

to service.

A battery may be tested, whether fully charged or not, via

conductance test. In order to perform a load test, however, the

•

CHARGE & RETEST - Fully charge the battery and retest.

battery must be fully charged.

•

REPLACE BATTERY - Replace the battery and retest.

VOLTMETER TEST

•

BAD CELL-REPLACE - Replace the battery and retest.

The voltmeter test provides a general indicator of battery state

•

BATTERY NOISE - Remove surface charge from battery

of charge or condition. Check the voltage of the battery to verify

and retest.

that it is in a 100% fully charged condition. Refer to Table 1-5.

If the open circuit (disconnected) voltage reading is below

NOTES

12.6V, charge the battery and then recheck the voltage after

•

A REPLACE BATTERY test result may also mean a poor

the battery has set for one to two hours. If the voltage reading

connection between the battery cables and the vehicle.

is 12.7V or above, perform the LOAD TEST described in this

After disconnecting the battery cables from the battery,

section.

retest the battery using the out-of-vehicle test before

replacing.

Table 1-5. Voltmeter Test For Battery Charge Conditions

•

Connect the tester directly to the lead terminals of the

VOLTAGE (OCV)

STATE OF CHARGE

battery, and not the bolts.

12.7

100%

12.6

75%

ed02811

12.3

50%

12.0

25%

11.8

CONDUCTANCE TEST

PART NUMBER

TOOL NAME

HD-48053

ADVANCED BATTERY CONDUCT-

ANCE AND ELECTRICAL SYSTEM

ANALYZER

Test the battery using the ADVANCED BATTERY CONDUCT-

ANCE AND ELECTRICAL SYSTEM ANALYZER (Part No. HD-

48053). Perform a battery test as follows:

Figure 1-22. Battery Test Results Printout

1. Connect the HD-48053 analyzer leads to the vehicle bat-

tery lead terminal, not to bolt or wire terminal.

NOTE

LOAD TEST

Connect the tester directly to the lead terminals of the battery,

To load test the battery, proceed as follows:

and not the bolts.

2. Follow the instructions in the analyzer instruction manual

to perform a battery test.

Disconnect negative (-) battery cable first. If positive (+)

The test results will include a decision on the battery condition

cable should contact ground with negative (-) cable con-

and the measured state of charge.

nected, the resulting sparks can cause a battery explosion,

which could result in death or serious injury. (00049a)

1. Remove battery from motorcycle.

2. Always fully charge the battery before testing or test

readings will be incorrect. Load testing a discharged bat-

tery can also result in permanent battery damage.

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

before testing.

1-26 2008 Sportster Diagnostics: Starting / Charging

6. Install the battery in the motorcycle.

Turn battery load tester OFF before connecting tester

ed02876

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)

4. See Figure 1-23. Connect tester leads to battery posts

and place induction pickup over negative (black) cable.

NOTE

To avoid load tester and/or battery damage, do not leave the

load tester switch turned ON for more than 20 seconds.

5. Refer to Table 1-6. Load battery at 50% of CCA rating

using the load tester. Voltage reading after 15 seconds

should be 9.6V or more at 70° F (21° C).

Turn battery load tester OFF before disconnecting tester

cables to battery terminals. Disconnecting tester cables

with load tester ON can cause a spark and battery explo-

sion, which could result in death or serious injury. (00253a)

1. Load tester

Connect positive (+) battery cable first. If positive (+) cable

2. Induction pickup

should contact ground with negative (-) cable connected,

3. Battery

the resulting sparks can cause a battery explosion, which

could result in death or serious injury. (00068a)

Figure 1-23. Load Test Battery

Table 1-6. Battery Load Test

Do not over-tighten bolts on battery terminals. Use

recommended torque values. Over-tightening battery ter-

COLD CRANKING

100%

50%

minal bolts could result in damage to battery terminals.

AMPERAGE (CCA)

(00216a)

Sportster models

205

102.5

2008 Sportster Diagnostics: Starting / Charging 1-27

NOTES

1-28 2008 Sportster Diagnostics: Starting / Charging

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