Harley Davidson 2018 softail models. Service manual — page 35
The voltmeter test provides a general indication of battery state of charge or condition. Check the voltage of the battery to
verify that it is in a 100% fully charged condition. Refer to Table 1.
If the open circuit (disconnected) voltage reading is below 12.6V, charge battery and then check voltage after battery has
set for 1-2 hours. If voltage reading is 12.7V or above, perform a load test. See Load Test.
Table 1. Voltmeter Test For Battery Charge Conditions
VOLTAGE
STATE OF CHARGE
12.7
100%
12.6
75%
12.3
50%
12.0
25%
11.8
0%
Special Tools
Description
Part Number
Qty.
HD BATTERY DIAGNOSTIC
GRX-3110HD
1
STATION
Test battery using the HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD).
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. Disconnect and remove battery.
2. Read GRX instruction manual before performing a battery test.
3. Connect HD BATTERY DIAGNOSTIC STATION (Part Number:GRX-3110HD) leads to the battery terminals.
4. Test results will include a decision on battery condition and measured state of charge. See Figure 1. The GRX
printer will provide a printout including test results:
a. GOOD BATTERY - Return battery to service.
b. REPLACE BATTERY - Replace battery.
Figure 1. Battery Test Results Printout (Typical)
WARNING
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)
1. With vehicle battery on a bench, charge battery using an
automatic, constant monitoring battery charger approved
for AGM batteries.
NOTE
Always fully charge battery before testing or test
readings will be incorrect. Load testing a discharged
battery can also result in permanent battery damage.
WARNING
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)
2. See Figure 1. 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 load tester switch turned ON for more than 20
seconds.
WARNING
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 explosion, which could result in death
or serious injury. (00253a)
WARNING
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable
connected, the resulting sparks can cause a battery
explosion, which could result in death or serious
injury. (00068a)
NOTICE
Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening
battery terminal bolts could result in damage to
battery terminals. (00216a)
3. Load battery at 50 percent of CCA rating using load tester.
Voltage reading after 15 seconds should be 9.6V or more
at 21 °C (70 °F). Refer to Table 1.
1
Load tester
2
Induction pickup
3
Battery
Figure 1. Load Test Battery
Table 1. Battery Load Test
COLD CRANKING
100%
50%
AMPERAGE (CCA)
Softail models
315
155
Battery voltage is supplied to the BCM at all times through the main fuse. The engine stop switch also functions as the
ignition switch.
When the engine stop switch is in the RUN position, a CAN message is sent, signaling the BCM that the switch is in the
RUN position. If CAN communication is interrupted while the engine is running, the BCM checks for the signal from the
redundant engine stop switch circuit.
When the start switch is pressed, a CAN message is sent to the BCM. The BCM provides power to the starter solenoid.
This energizes the solenoid and full battery power is sent to the starter. The BCM disables the starter solenoid if the start
switch is pressed for more than 10 seconds.
Starter
The starter receives power from the battery through the starter solenoid and is grounded through the starter case.
When the starter solenoid is energized, two events happen:
The plunger pulls inward which allows current to flow to the starter motor.
The pinion gear engages with the ring gear on the clutch shell.
With the starter motor turning, the rotation is transferred:
The starter armature gear transfers rotation to the idler gear.
The idler gear transfers rotation to the starter clutch.
The starter clutch transfers rotation through a spline gear to the starter drive shaft which also drives the pinion
gear.
The pinion gear transfers its rotation to the ring gear on the clutch shell.
The primary chain drives the alternator rotor sprocket on the end of the crankshaft.
The starter clutch has a one-way clutch. When the engine starts, it allows the clutch shell and sprocket to spin freely
without causing any damage to the starter motor. After the engine starts and the start switch is released, the plunger
returns to its normal position, disengaging the pinion gear from the clutch shell and sprocket.
1
Engine harness [145]
2
ABS EHCU [166]
3
Rear HO2S [137]
4
Starter solenoid [128]
5
Rear WSS [168]
Figure 1. Behind Right Side Cover
Starter Solenoid
See Figure 1. The starter solenoid provides power to the starter. The solenoid is a means of controlling a high
amperage device with a low amperage switch. The low amperage switch in this circuit is the BCM. The BCM sends
voltage to the starter solenoid making a magnetic field that pulls a larger circuit closed, allowing voltage to the starter.
Engine Stop Switch
The engine stop switch is located on the right hand controls. The engine stop switch also functions as the ignition
switch. With the engine stop switch in the RUN position, a CAN message is sent, signaling the BCM that the switch is
in the RUN position. If CAN communication is interrupted while engine is running, a redundant engine stop switch
circuit allows communication to the BCM.
Start Switch
The start switch is a push button switch located in the right hand controls. When the start switch is pressed, a CAN
message is sent to the BCM.
BCM
The BCM supplies ignition and accessory power to most of the vehicle. It controls the lighting along with other
functions by using the switches as inputs and the power circuits for the lights and other electrical loads as outputs.
Battery
WARNING
Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM
CHILDREN. (00063a)
WARNING
Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in
warning, could result in death or serious injury. (00064a)
WARNING
Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)
WARNING
If battery becomes hot, gassing or spewing of electrolyte can occur, which could cause death or serious injury.
Unplug or turn OFF the charger until battery cools. (00412b)
WARNING
Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after
handling. (00019e)
NOTICE
If battery releases an excessive amount of gas during charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or damage. (00413b)
The AGM batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid
batteries.
The battery is recharged by the alternator and kept from overcharging by the regulator during use.
Battery condition can be determined by a voltage test, a charging and a load test. See General.
The battery must be fully charged to perform a conductance test or a load test.
Grinding Noise or Erratic Starting
1. Remove starter.
2. Inspect the starter mounting surface and mating area on inner primary for arcing and pitting. This condition is
caused by insufficient ground and or clamp load.
3. Clean mating surfaces.
4. Inspect starter pinion gear. Replace starter if damaged.
5. Install starter.
Connector Information
For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see General.
Figure 2. Starting Circuit
Troubleshooting tables contain detailed procedures to solve and correct problems. Follow Description and Operation to
diagnose starting system problems. The Voltage Drop procedure will help you to locate poor connections or components
with excessive voltage drops.
Table 1. Starter Testing Diagnostic Faults
POSSIBLE CAUSES
Short to voltage at starter solenoid
Start switch malfunction
Short to voltage on BCM supply circuit
1. Starting System Operational Test
1. Press start switch.
2. Does starter spin?
a. Yes, starter spins but does not engage. See Starter Spins But Does Not Engage.
b. Yes, starter stalls or spins too slowly. See Starter Stalls or Spins Too Slowly.
c. Yes, starter runs on. Go to Test 3.
d. No. Go to Test 2.
2. Noise Test
1. While listening for clicking noise from starter solenoid, press start switch.
2. Is there a click?
a. Yes, starter solenoid clicks. See Starter Solenoid Clicks.
b. No. See Nothing Clicks.
3. Starter Solenoid Test
1. Disconnect starter solenoid [128].
2. Does starter stop?
a. Yes. Go to Test 4.
b. No. Replace starter assembly.
4. Checking DTCs Test
1. Check DTCs.
2. Is DTC B2122 present?
a. Yes. See Description and Operation.
b. No. Replace BCM.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
Table 1. Nothing Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Open fuse
Neutral switch malfunction
Open neutral circuit
Open ignition switch circuit
Open starter solenoid power circuit
Poor starter housing ground
NOTE
Verify that vehicle is in neutral.
Check that key fob is present and in working order (if security equipped).
Verify the engine stop switch is in RUN position.
1. Battery Test
1. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. Ignition Circuit Test
1. Turn IGN ON.
2. Do odometer, headlamp and tail lamps illuminate?
a. Yes. Go to Test 3.
b. No. Odometer is inoperative, but headlamp and tail lamps illuminate. See Description and
Operation.
c. No. Odometer, headlamp and tail lamps inoperative. See No Vehicle Power: DTC U0140.
3. Starter Solenoid Circuit Test
1. Turn IGN OFF.
2. Disconnect starter solenoid [128].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), during the first 4-5 seconds, while start button is
pressed, test voltage between [128B] (R/BK) wire and ground.
5. Is battery voltage present?
a. Yes. Go to Test 4.
b. No. Go to Test 5.
4. Starter Ground Test
1. Remove starter attaching bolts.
2. Clean bolts and starter base, install starter bolts.
3. Does engine crank?
a. Yes. Engine cranks at normal speed. Repair complete.
b. Yes. Engine cranks, but at a slower speed. See Starter Current Draw Test.
c. No. Replace starter assembly.
5. Neutral Switch Test
1. Observe neutral lamp.
2. Is neutral lamp illuminated?
a. Yes. Go to Test 6.
b. No. See Neutral Lamp Inoperative.
6. Starter Solenoid Circuit Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2)
between wire harness [242B] and BCM [242A]. See How To Use Diagnostic Tools.
3. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on BOB.
4. Test resistance between BOB terminal L2 and [128B].
5. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open in (R/BK) wire.
7. BCM Test
1. Turn IGN OFF.
2. Remove main fuse [5].
3. Disconnect BCM and replace with known good BCM.
4. Install main fuse.
5. Turn IGN ON.
6. Attempt to start vehicle.
7. Does engine crank?
a. Yes. Replace BCM.
b. No. Replace RHCM.
Table 1. Starter Solenoid Clicks Diagnostic Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Poor battery cable connections
Mechanical binding
1. Battery Test
1. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. 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. Go to Test 3.
b. No. Go to Test 4.
3. 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.
b. No. Replace starter assembly.
4. Starter Ground Circuit Voltage Drop Test
1. Perform voltage drop test from battery (-) terminal to chassis 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. Go to Test 5.
b. No. Go to Test 6.
5. Starter Ground Test
1. Remove starter attaching bolts.
2. Clean bolts and starter base, install starter bolts.
3. Does engine crank?
a. Yes, engine cranks at normal speed. Repair complete.
b. Yes, engine cranks, but at a slower speed. See Starter Current Draw Test.
c. No. Replace starter.
6. Starter Draw Test
1. Perform Starter Current Draw Test on motorcycle. See 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. Go to Test 7.
b. No. Replace starter.
7. Mechanical Binding Test
1. Remove spark plugs and place transmission in sixth gear.
2. Raise vehicle.
3. Rotate rear wheel.
4. Check for engine binding in the primary and/or crankshaft.
5. Is engine binding?
a. Yes. Repair as needed.
b. No. Replace starter assembly.
Table 1. Starter Spins But Does Not Engage Diagnostic Faults
POSSIBLE CAUSES
Starter clutch assembly
Clutch shell and/or starter pinion damage
1. Pinion Gear and Clutch Shell Test
1. Remove primary cover.
2. Inspect for damage to starter pinion gear and clutch shell and sprocket.
NOTE
Inspect ACR operation before installation of new starter clutch assembly.
3. Is damage present?
a. Yes. Replace starter assembly or clutch shell and sprocket.
b. No. Replace starter assembly.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
ECM CABLE
HD-50390-4
1
ECM OVERLAY
HD-50390-4-P
1
Table 1. Starter Stalls or Spins Too Slowly Diagnostic Faults
POSSIBLE CAUSES
Low battery
Starter malfunction
Starter solenoid malfunction
Poor connections at starter ground
Poor battery cable connections
1. Battery Test
1. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. Starter Stud Voltage Drop Test
1. Perform voltage drop test from battery (+) terminal to starter solenoid terminal 2. See Voltage Drop.
2. Is voltage drop greater than 1.0V?
a. Yes. Go to Test 7.
b. No. Go to Test 3.
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. Go to Test 4.
b. No. Go to Test 5.
4. Chassis Ground Circuit Voltage Drop Test
1. Perform voltage drop test from battery (-) terminal to chassis 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. Clean bolts and starter base, install starter bolts.
5. ACR Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and ECM CABLE (Part Number:HD-50390-4)
between wire harness [78B-1], [78B-2], [78B-3] and [78A-1], [78A-2], [78A-3]. See How To Use Diagnostic
Tools.
3. Verify ECM OVERLAY (Part Number:HD-50390-4-P) is in position on BOB.
4. Turn IGN ON.
5. Using TEST CONNECTOR KIT (Part Number:HD-41404), jumper between BOB [78-2] terminals 4 and 10.
6. Do ACRs click?
a. Yes. Go to Test 6.
b. No. Replace front and rear ACR solenoids.
6. Starter Draw Test
1. Perform Starter Current Draw Test on motorcycle. See 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 transmission in 6th gear, rotate rear wheel. Check for engine,
primary and/or crankshaft bind.
b. No. Replace starter.
7. 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.
b. No. Replace starter assembly.
The starter solenoid circuit is controlled and monitored by the BCM. The BCM receives a CAN message from the start
switch in the RHCM to engage the starter. Voltage is sent from the BCM to the starter solenoid [128] (R/BK) wire. The
BCM disables the starter solenoid if the start switch is pressed for more than 10 seconds.
Table 1. Code Description
DTC
DESCRIPTION
B2121
Starter output open
B2122
Starter output shorted high
B2123
Starter output shorted low
B2124
Starter output overloaded
Conditions for Setting
DTC B2121 will set if the starter solenoid circuit draws less than 600 milliamps.
DTC B2124 will set if the starter solenoid circuit draws more than 12 amps.
Connector Information
For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see General.
Figure 1. Starter
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
Table 1. DTC B2121 Diagnostic Faults
POSSIBLE CAUSES
Open in starter circuit
Open in starter solenoid
1. Starter Solenoid Circuit Test
1. Turn IGN OFF.
2. Disconnect starter solenoid [128].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), during first 4-5 seconds, while start button is
pressed, test battery voltage between [128B] (R/BK) and ground.
5. Is battery voltage present?
a. Yes. Replace starter assembly.
b. No. Go to Test 2.
2. Starter Solenoid Supply Voltage Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2)
between wire harness [242B] and [242A]. See How To Use Diagnostic Tools.
3. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on BOB.
4. During first 4-5 seconds, while start button is pressed, test voltage between BOB terminal L2 and ground.
5. Is voltage present?
a. Yes. Repair open in (R/BK) wire between [242B] terminal L2 and [128B].
b. No. Replace BCM.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
Table 1. DTC B2122 Diagnostic Faults
POSSIBLE CAUSES
Short in starter circuit
Short in starter solenoid
1. Starter Solenoid Circuit Test
1. Turn IGN OFF.
2. Disconnect starter solenoid [128].
3. Turn IGN ON.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test voltage between [128B] (R/BK) and ground.
5. Is battery voltage present?
a. Yes. Go to Test 2.
b. No. Replace starter assembly.
2. Starter Solenoid Supply Voltage Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2)
between wire harness [242B] and [242A]. See How To Use Diagnostic Tools.
3. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on BOB.
4. Turn IGN ON.
5. Without pressing start button, test voltage between BOB terminal L2 and ground.
6. Is voltage present?
a. Yes. Repair short to voltage in (R/BK) wire between [242B] terminal L2 and [128B].
b. No. Replace BCM.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
Table 1. DTC B2123 Diagnostic Faults
POSSIBLE CAUSES
Short in starter circuit
Short in starter solenoid
1. Starter Solenoid Supply Resistance Test
1. Turn IGN OFF.
2. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2) to wire
harness [242B], leaving [242A] disconnected. See How To Use Diagnostic Tools.
3. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on BOB.
4. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between BOB terminal L2 and
ground.
5. Is continuity present?
a. Yes. Repair short to ground in (R/BK) wire between [242B] terminal L2 and [128B].
b. No. Replace BCM.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
BREAKOUT BOX
HD-50390-1
1
BCM CABLE
HD-50390-2
1
BCM OVERLAY
HD-50390-2-P
1
Table 1. DTC B2124 Diagnostic Faults
POSSIBLE CAUSES
Short in starter circuit
Starter solenoid malfunction
Corrosion at connector
1. Starter Solenoid [128] Test
1. Turn IGN OFF.
2. Disconnect starter solenoid [128].
3. Inspect [128] and (R/BK) wire for damage or corrosion.
4. Is any present?
a. Yes. Repair or replace [128] and (R/BK) wire.
b. No. Go to Test 2.
2. Starter Solenoid Circuit Test
1. Using TEST CONNECTOR KIT (Part Number:HD-41404), test continuity between [128B] (R/BK) wire and
ground.
2. Is continuity present?
a. Yes. Go to Test 3.
b. No. Replace starter assembly.
3. Starter Solenoid Supply Continuity Test
1. Connect BREAKOUT BOX (Part Number:HD-50390-1) and BCM CABLE (Part Number:HD-50390-2) to wire
harness [242B], leaving [242A] disconnected. See How To Use Diagnostic Tools.
2. Verify BCM OVERLAY (Part Number:HD-50390-2-P) is in position on BOB.
3. Test continuity between BOB terminal L2 and ground.
4. Is continuity present?
a. Yes. Repair short to ground in (R/BK) wire between [242B] terminal L2 and [128B].
b. No. Replace BCM.
Special Tools
Description
Part Number
Qty.
FLUKE AC/DC CURRENT PROBE
HD-39617
1
NOTE
Engine temperature should be stable and at room temperature.
Battery should be fully charged.
Check starter current draw with FLUKE AC/DC CURRENT PROBE (Part Number:HD-39617). See How To Use
Diagnostic Tools.
1. Verify that transmission is in neutral.
2. Disconnect CKP sensor [79].
3. Clamp FLUKE AC/DC CURRENT PROBE (Part Number:HD-39617) around positive battery cable to starter
solenoid.
NOTE
After the start button has been pressed for 10 seconds, the BCM will stop voltage to the starter solenoid automatically.
4. With IGN ON, press start button and read ammeter. Disregard initial high current reading. This is normal when
engine is first turned over.
5. Did starter current draw exceed 250A?
a. Yes. Perform a bench test. See Free Running Current Draw Test.
b. No. Starter current is within specification.
Special Tools
Description
Part Number
Qty.
FLUKE AC/DC CURRENT PROBE
HD-39617
1
1.
Place starter in vise. Use a clean shop towel to prevent
scratches or other damage.
2.
See Figure 1. Attach one heavy jumper cable (6 gauge
minimum).
a. Connect one end to starter mounting flange.
b. Connect the other end to battery (-) terminal of a fully
charged battery.
3.
Connect a second heavy jumper cable (6 gauge
minimum).
a. Connect one end to battery (+) terminal of battery.
b. Connect other end to battery terminal on starter.
Clamp FLUKE AC/DC CURRENT PROBE (Part
Number:HD-39617) around cable.
CAUTION
Keep fingers and clothing away from starter gear to
prevent personal injury. (00613b)
4.
Connect a smaller jumper cable (14 gauge minimum).
a. Connect one end to positive (+) terminal of battery.
b. Connect other end to solenoid relay terminal [128].
5.
Check ammeter reading.
a. Ammeter should show 90A maximum.
b. If reading is higher, replace starter.
c. If starter current draw on vehicle was over 250A and
this test was within specification, possible causes
may be ACR malfunction, engine modifications, or
powertrain binding.
1
Mounting flange
2
Battery
3
Current probe
4
Multimeter
5
Relay terminal
6
Batter terminal
Figure 1. Free Running Current Draw Test
The charging system is the source of electric current that supplies power to run the ignition, lights, accessories and
charges 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 matches the output voltage to the battery voltage as engine speed varies.
Even though the alternator provides additional voltage at all engine speeds, avoid idling the engine for extended periods of
time.
Alternator
The alternator consists of two main components:
The rotor which mounts to the primary side of the crankshaft.
The stator which is attached to the crankcase half.
Voltage Regulator
See Charging System Circuit. The voltage regulator is a series regulator. The circuit combines the functions of
rectifying and regulating.
Battery
Test for a weak or dead battery. Battery must be fully charged in order to perform a battery diagnostic test, load test or
starting or charging tests. See General.
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 be clean and tight. Verify both AC and DC connectors are fully inserted and locked with the
regulator latch.
Connector Information
For additional information about the connectors in the following diagram(s) and diagnostic procedure(s), see General.
1
Fuse block
2
Stator
3
Voltage regulator
4
GND2
5
Engine GND
6
Starter
Figure 1. Charging System Circuit
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
Table 1. Low or No Charging Diagnostic Faults
POSSIBLE CAUSES
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. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. Off Idle Voltage Test
1. Start engine and run at 3000 rpm for 30 seconds.
2. With the engine still running at 3000 RPM, test battery voltage.
3. Is voltage above 14V?
a. Yes. Charging system working properly.
b. No. Go to Test 3.
3. AC Output Test
1. Perform AC output test. See Battery Charging Tests.
2. Did output test pass?
a. Yes. Go to Test 6.
b. No. Go to Test 4.
4. Stator Test
1. Perform stator test. See Battery Charging Tests.
2. Is the stator good?
a. Yes. Go to Test 5.
b. No. Replace stator.
5. Rotor Inspection Test
1. Turn IGN OFF.
2. Inspect rotor magnets for damage.
3. Remove compensator assembly and inspect rotor and shaft splines for excessive wear.
4. Verify stator bolts have not backed out and contacted rotor.
5. Is rotor in good condition?
a. Yes. Go to Test 6.
b. No. Replace rotor.
6. Voltage Regulator Power Circuit Test
1. Disconnect voltage regulator [77].
2. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [77B] terminal (+) and
battery.
3. Is resistance less than 0.5 ohm?
a. Yes. Go to Test 7.
b. No. Repair open wire between voltage regulator [77B] terminal (+) and battery.
7. Voltage Regulator Ground Circuit Test
NOTE
Voltage regulator ground must have a clean, tight connection for proper grounding.
1. Test resistance between [77B] terminal (-) and ground 2.
2. Is resistance less than 0.5 ohms?
a. Yes. Replace voltage regulator.
b. No. Repair open wire between voltage regulator [77B] terminal (-) and ground 2 (BK) wire.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
Table 1. Overcharging Diagnostic Faults
POSSIBLE CAUSES
Voltage regulator malfunction
Open in ground circuit
1. Battery Voltage Test
1. Start engine and run at 3000 rpm, test battery voltage.
2. Is voltage above 15.5V?
a. Yes. Go to Test 2.
b. No. Charging system working properly.
2. Voltage Regulator Ground Circuit Test
NOTE
Voltage regulator ground must have a clean and tight connection for proper grounding.
1. Turn IGN OFF.
2. Disconnect voltage regulator [77].
3. Using TEST CONNECTOR KIT (Part Number:HD-41404), test resistance between [77B] terminal (-) and
ground 2.
4. Is resistance less than 0.5 ohms?
a. Yes. Replace voltage regulator.
b. No. Repair open wire between [77B] terminal (-) and ground 2 (BK) wire.
Table 1. 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 discharged because motorcycle was not operated for a long period
1. Battery Test
1. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. Amp Draw Test
1. Perform milliampere draw test. See Battery Charging Tests.
2. Did test exceed maximum draw?
a. Yes. Repair excessive draw and run test again.
b. No. System is working properly.
Table 1. Battery Runs Down During Use Diagnostic Faults
POSSIBLE CAUSES
Battery
Excessive accessory draw
Accessories on when idling or low rpm riding for extended period
1. Battery Test
1. Perform battery test. See General.
2. Did battery pass test?
a. Yes. Go to Test 2.
b. No. Replace battery.
2. Total Current Draw Test
1. Perform total current draw and output test. See Battery Charging Tests.
2. Does charging system exceed current draw by 3.5A?
a. Yes. System is working properly.
b. No. System accessory power requirements exceed charging system capability.
Special Tools
Description
Part Number
Qty.
TEST CONNECTOR KIT
HD-41404
1
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.
1. Security system: Enable service mode before performing test. See General.
2. Turn IGN OFF.
3. Verify all lights and accessories are OFF.
4. Disconnect the security siren (if equipped).
5. Remove main fuse.
NOTE
With IGN OFF, an initial current draw will occur directly after connecting meter. This should drop to the values
shown in Table 1 in less than 30 seconds.
6. See Figure 1. Using TEST CONNECTOR KIT (Part Number:HD-41404), connect ammeter to main fuse
socket terminals. With this arrangement, you will also pick up any regulator drain.
7. Observe current reading.
a. Add the maximum draw values found in table for the components equipped on the vehicle being tested.
If the reading observed on the ammeter is less than the sum of the maximum draw for the components,
the draw is within specification. Refer to Table 1.
b. A higher ammeter reading indicates excessive current draw. Locate the component or accessory with
high draw by unplugging one at a time while observing the meter reading.
Table 1. Milliampere Draw Test
ITEM
MAXIMUM DRAW IN MILLIAMPERES
LHCM
0.5
RHCM
0.5
IM
0.5
Tachometer (if equipped)
0.5
Regulator
1.0
ABS (if equipped)
1.0
BCM
1.0
ECM
1.0
Security siren (if equipped)
20.0*
* Siren will draw for 2-24 hours from time motorcycle battery is connected and 0.05 mA once siren battery is
charged. Disconnect siren during milliampere draw test.
1
Ammeter
2
Fuse block [64B]
3
Voltage regulator
Figure 1. 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, use an ammeter with current probe.
WARNING
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 Figure 2. Connect load tester.
a. Remove battery.
b. Install battery terminal adapters HD-50977 to the battery.
c. Using two foot long, 4-gauge jumper cables with terminal lugs, connect the battery to the vehicle.
NOTE
Use a 15 cm (6 in) piece of wiring sleeve to cover the positive cable connection to prevent shorting to the
frame.
d. Connect negative and positive load tester leads to battery terminals.
e. Place load tester induction pickup over battery negative cable.
2. With IGN OFF, disconnect voltage regulator [77].
3. Start engine.
4. Turn all continuously running lights and accessories ON (headlamp on high beam).
5. Run engine at 3000 rpm and make note of the current draw.
6. Turn IGN OFF.
7. 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 35-44A. 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.
1
Induction pickup
2
Load tester leads
3
Jump cables from battery to vehicle
Figure 2. Check Current Draw (Ignition On)
Stator Test
1. Turn IGN OFF.
2. See Figure 3. Using TEST CONNECTOR KIT (Part Number:HD-41404), connect an ohmmeter.
a. Disconnect voltage regulator [47] from alternator stator wiring.
b. Insert one ohmmeter lead into a stator connector socket.
c. Attach the other lead to a suitable ground.
3. Test 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 Figure 4. Remove ground lead. Test resistance across stator [47B] terminals 1-2, 2-3 and 3-1.
a. Resistance across all stator terminals should be 0.1-0.3 ohm.
b. If resistance is out of range, replace stator.
NOTE
When testing resistance (ohms), compensate for test lead resistance before performing the measurement. Select
the ohms position and touch the test leads together. See the multimeter user's manual to zero display or
manually subtract test lead resistance from the measured circuit's value.
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