Electrical Systems
7.16
Electrical Testing
Charging System Testing -- Unregulated Voltage -- Carbureted Models
1. Open electrical box to gain access to components.
2. T urn multimeter to V olts AC position.
3. Disconnect the Yellow and Red/Pur wires from the terminal board and CDI module. Connect one of the tester
leads to the Yellow stator wire and the other lead to the Red/Pur stator wire.
4. Start the engine. While observing the voltage reading, increase engine speed to about 3000 RPM. Reading
should be above 20 VAC. If output is low, test the stator battery charge coils with an ohmmeter and compare to
specification: .75 ohms.
Charging System Testing -- Regulated Voltage -- Carbureted Models
1. T urn multimeter to volts DC and connect the leads across the battery terminals.
2. Start and briefly run the engine at 3000 RPM. Measured voltage should be around 14--14.5 VDC. A higher
reading may indicate a regulator problem or a poor ground. A lower reading may indicate an excessive
system load, stator problem, or a faulty regulator or wire connection.
3. If DC voltage is low, check all connections and charge the battery prior to re--test.
NOTE: The regulator/rectifier is located within the LR module. It is not serviceable and must be replaced if sus-
pect.
Start / Stop Switch Testing -- All Mod els
1. Set multimeter to Ohms position.
2. Unplug the start / stop switch harness from the connector located under the handle bar cover.
3. Connect one of the test leads to the Red/Pur pin, and the other to the Yellow/Red pin.
4. Press the start / stop button. Resistance readings should be .3 ohms or less. Replace switch assembly if
readings are above expected range.
Tether Switch Testing -- All Mo d els
1. Set multimeter to Ohms position.
2. Unplug the start / stop switch harness from the connector located under the handle bar cover.
3. Connect one of the test leads to the Black/Yellow pin, and the other to the Black pin.
4. Disconnect the tether cord. Resistance readings should be .3 ohms or less. If resistance readings are out of
range, replace the switch.
5. Connect the tether cord. An OPEN reading should be indicated on the multimeter. If not, replace the switch.
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