10.24
ELECTRICAL
Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good
condition, connected and not kinked or pinched.
Using a multitester set on D.C. volts, measure the
battery open circuit voltage (See earlier test). It
should be 12.4 volts or more. Is it?
With the transmission in Park, start the engine and
increase RPM to between 3000 and 4000. Read
battery voltage with the multitester. Readings
should increase to between 13 and 14.6 VDC.
Are they?
Perform system Break Even Amperage Test"
Does charging occur as specified?
Meter Setting DC Amps
Meter Setting DC Volts
Ohm stator wires If bad, replace stator. If good,
continue with alternator output test.
Disconnect the wires from the regulator/rectifier.
Using a multitester, perform an Alternator Output
(AC amp) test. See test procedure on Page 10.20
for procedure. Is output above 7 amps?
Meter Setting AC Amps
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?
Meter Setting: DC Volts
If all of the previous tests indicate a good
condition, but the charging voltage does not rise
above battery voltage at the connector or wire
harness, replace the voltage regulator.
Yes
Yes
Yes
No
No
Remove the battery and properly service.
Reinstall the fully charged battery or a fully
charged shop battery.
No
Yes
Yes
No
No
Check Key Off Current Draw
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
below the “Break Even” RPM.
Continued problems would call for
battery inspection.
Inspect the wiring harness between the
panel and the stator for damage. If no
damage is found, remove the recoil and
flywheel. Inspect the flywheel magnets,
stator coils and stator wire harness for
damage. Repair or replace any damaged
components.
Check regulator/rectifier connections and
ground, battery connections, circuit
breaker and connecting wires. Repair or
replace faulty wiring or components.
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