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CHARGING SYSTEM TESTING
Whenever charging system problems are suspected, proceed with the following system checks:
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (see
procedure later in chapter). It should be
12.4 volts or more. Is it?
Yes
Meter Setting: DC Volts
With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the
multitester. Readings should be between
13.0 and 14.6 Vdc
Are they?
No
Meter Setting: DC Amps
Perform system "Break Even Amperage"
test outlined on Page 10.18.
Does charging occur as specified?
No
Meter Setting: AC Amps
Disconnect the wires leading from the regu-
lator/rectifier. Using a multitester, perform an
Alternator Output (AC amp) test. See test
procedure on Page 10.18 for procedure.
Is output above 5 amps?
Yes
Meter Setting: DC Volts
Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery
voltage must be present on red wire terminal
on harness side of voltage regulator connector.
Is it?
Yes
If all of the previous tests indicate a
good condition, but the charging voltage
does not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
No
or a fully charged shop battery.
Check Key off Current Draw
Yes
Refer to Page 10.18.
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
Yes
below the "Break Even" RPM. Con-
tinued problems would call for battery
Inspect the wiring harness be-
tween the panel and the stator for
damage. If no damage is found,
No
remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
tor coils and stator wire harness
for damage. Repair or replace
any damaged components.
Check regulator/rectifier connections
No
and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
ELECTRICAL
inspection.
10.17
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Troubleshooting
