ALTERNATOR CHARGING RATE AND VOLTAGE REGULATOR
The alternator output is controlled by the voltage regulator. This unit requires no scheduled mainte-
nance. If any electrical system trouble is experienced that you think might be related to the alternator
or voltage regulator, contact an authorized Big Bear Choppers Dealer.
BATTERY SERVICING AND INSTALLATION
Battery connections should be cleaned and tightened every 2,500 miles. To service the battery, re-
move the seat, disconnect battery cables (negative rst, positive last), and clean the cable connec-
tors and battery terminal with a wire brush or sandpaper to remove oxidation. Connect the cables
to the proper terminals (positive rst, negative last). Do not over tighten terminal connections. Coat
the terminals with corrosion inhibitor. Batteries can lose some of their charge even with the ignition
turned off. Discharge rate depends on the storage temperature and the condition of the battery. After
30 days of non use, the battery may not have sufcient cranking power to start the motorcycle. Use
a motorcycle specic charger.
SPARK PLUG, PLUG WIRE INSPECTION AND REPLACEMENT
Inspect and/or replace the spark plugs at the 500 mile mark then every 2,500 miles. To disconnect
the spark plug wires from the plugs, pull on the molded connector boots. The connection is a snap
type. Grasp the rubber wire boot, not the wire. Pulling on the wire may damage the internal conduc-
tor. The spark plug gap should be .040. Make sure that the new spark plugs are the same type as the
ones being replaced. Autolight spark plugs. Spark plugs should be torqued to 14 ft. lbs. If the engine
seems to be running on only one cylinder, check the spark plug wire connection at both ends.
HEADLIGHT REPLACEMENT
The headlight has a replaceable quartz halogen bulb. When replacing a halogen bulb never touch
the glass portion with your bare ngers as oil contamination will reduce bulb life. Do not attempt to
remove bulb while it is still hot.
Do not replace or use any noncompliant or unauthorized Big Bear Choppers electrical components.
This could lead to one or more electrical faults or system failures. This will void the electrical warranty.
3.3 General Inspection
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