2004 Harley Davidson FLHTC - FLHTCI Electra Glide classic - Answered Questions & Fixed issues
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2/27/2015 2:20:39 PM •
2004 Harley...
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Answered
on Feb 27, 2015
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86 views
How to test voltage regaltor
Voltage Regulator Bleed Test if the battery is discharging wile sitting unused.
Ensure that the regulator is connected to battery, then unplug voltage regulator connector at the engine crankcase (the stator connector) to isolate the regulator from the stator windings. THEN using a test light, touch one probe to a suitable ground and touch the other to the regulator pins, one at a time. IF the tester light glows at any time the regulator is defective (shorted) and needs to be replaced.
OTHERWISE:
Motorcycle voltage regulator connections must be clean and tight for proper operation so it must be verified that both the AC (stator) connections and the DC (battery supply side) connectors are clean, fully inserted and locked in place with the regulator latches (they should also be coated with dielectric grease to keep them clean and corrosion free).
The motorcycle voltage regulator is a series regulator that is also a rectifier that changes stator supplied alternating current (AC) to direct current (DC) which the battery system requires. If the charging system does not keep the battery properly charged both with regards to Voltage (between 13 VDC minimum and 15.5 VDC maximum) and the current supply at a high enough amperage to meet the system lighting, ignition, TSM/TSSM, security and accessory requirements plus a minimum of 3.5 more amps (3.5 amps more than the foregoing system requirements) there are a number of tests that can be done to ascertain why.
As the voltage regulator must have a good, clean, tight (and otherwise secure) ground connection for proper operation a Voltage Regulator Ground Circuit Test can be accomplished by connecting an ohmmeter to a known good ground (like the battery negative post) and the case of the regulator. If there is continuity with little resistance the ground is GOOD and nothing more needs to be done BUT if there is NO continuity or there is more than minimal resistance the ground will need to be fixed so there is a low resistance continuity by either locating and fixing the poor ground or adding a new grounding wire from the regulator case to a know good ground.
A Voltage Regulator Power Circuit Test can be accomplished by turning OFF the Ignition, disconnecting the voltage regulator and with an ohmmeter set to the Rx1 setting, testing for continuity between the voltage regulator wire harness supply terminal and the main fuse terminal (with the fuse removed) and if there is continuity present then the wiring circuit here is GOOD but if there is NO continuity then you will need to either find the open and repair it or replace the whole wire running from the voltage regulator to the main fuse.
As there should be no short circuit in the power supply from the regulator to battery (main fuse) wiring OR in the regulator internal circuitry continuity from these both need to be checked again with an ohmmeter set to the Rx1 setting. If the regulator to main fuse wiring connector is not disconnected from the regulator you can connect an ohmmeter with one lead on the regulator supply wire terminal end at the main fuse (with the main fuse removed) and the other lead to a known good ground. If there is NO continuity then you know that both the supply wire and the regulator are okay (as there is no short to ground). BUT if there is continuity then either the regulator or wiring or both is/are shorted to ground. To determine where there is a short circuit (i.e. either the wiring or the regulator internal circuitry) you must disconnect the DC side of the wiring harness (the connector at the DC side of the regulator) from the regulator and test between either or both ends of the wire i.e. from the regulator wire harness connector terminal and a known good ground and/or the main fuse terminal end of the wire and a known good ground. If there is any continuity the wire is shorted to ground and the short circuit must be found and repaired or the wire must be completely replaced. If there is no such continuity then the regulator DC supply terminal (with the DC side of the regulator connector disconnected) must be tested by putting one lead of an ohmmeter on the regulator terminal and the other on a known good ground. If there is continuity the regulator is shorted to ground and must be replaced. If there is a short in the wiring it is unlikely BUT the regulator could ALSO be internally shorted so it should also be checked either before or after any wiring short is located and repaired.
The voltage regulator must also properly regulate the rectified DC voltage supplied to the battery so that it is not less than 13 VDC or more than 15.5 VDC. If the regulator is not properly limiting supply voltage to the battery to 15.5 VDC or less it will be overcharging the battery. This can be tested for by operating the motorcycle engine at 3000 rpm while placing a voltmeter between the battery positive and negative posts and reading the supplied voltage. If the reading is greater than 15.5 VDC the regulator is defective and must be replaced. If the voltage is less than 15.5 VDC but more than 13 VDC the regulator and the rest of the charging system are operating correctly. If the supplied voltage is less than 13 VDC the AC side of the system must be tested and if the AC side is good but the supplied voltage at the battery is less than 13 VDC then the regulator is defective and must be replaced. If the AC side of the system is not providing correct AC supply then the stator must be tested and if it is bad, replaced and if it is good then the rotor inspected (cannot be electrically tested as it consists of permanent magnets but it could be inspected fro physical damage and roughly tested for strong magnetic force fields by using a ferrous metal object to see if the attraction of the magnets is strong or weak, but this is basically a better guess rather than a precise measurement). The rotor can also be physically inspected for physical signs of damage including signs of the center hole having become oval AND the stator bolts inspected for possibly having come loose and into contact with the rotor.
9/10/2014 7:43:41 AM •
2004 Harley...
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Answered
on Sep 10, 2014
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624 views
2004 FLHTC. The bike was hard starting. Checked battery, 12.8V. Now, it will not start. What could be the problem?
You could have a bad starter ground but more likely you have a bad solenoid. Do voltage drop testing to find the problem for sure.
First do a voltage reading on the battery and note what it is.
Using a voltmeter attach the red meter lead to the most positive part of the circuit, which would be the positive post of the battery and attach the black meter lead to the final destination or component in the circuit (if testing a starter circuit this would be the terminal on the starter, not the solenoid). THEN try to activate the starter and observe the meter reading. The meter will read the voltage dropped or the difference in potential between the source and the destination. An ideal circuit voltage drop reading would be 1 volt or less. If there is an open in the circuit (i.e. NO electricity is reaching the terminal) the voltmeter should read source voltage volts which means all the voltage was dropped. A normal good starter circuit should not show more than a one volt drop. If more than 1 volt is dropped there is a problem somewhere in the circuitry before the starter terminal. In this case leaving the red voltmeter lead on the battery positive post, move the negative voltmeter lead to the solenoid stud where the battery cable attaches and activate the starter circuit again. If the voltage reading is now 1 volt or less clean, repair, tighten the starter solenoid to starter terminal stud connections and test again and if no change clean/repair the internal solenoid contacts or replace the solenoid with a new/good one. If there is still a voltage drop greater than 1 volt move the negative voltmeter lead from the solenoid terminal stud to the actual battery cable terminal end at the solenoid terminal stud and again activate the starter circuit. If there is a 1 volt or less reading the battery cable terminal end and/or solenoid terminal stud and/or the connection between the two is faulty, loose, corroded or etc. Clean and tighten and retest. If there is still more than a 1 volt reading on the voltmeter the problem is a loose or corroded or otherwise bad connection between the battery cable terminal end and the battery positive post or the battery cable itself is bad. Clean and tighten the battery cable terminal and battery positive post and test again. If there is still more than a one volt reading on the voltmeter the battery cable is bad and will need to be replaced.
If there is less than a 1 volt reading when the test is done at the starter terminal the circuit up to that point is good so the next step will be to do a negative or ground circuit voltage drop test by connecting the negative or black voltmeter lead to the most negative point which is normally the negative battery post (or the closest thing thereto if, like some Sportsters, the battery post is hard or impossible to get to) and then connect the positive or red voltmeter lead to the starter mounting studs. Then activate the starter circuit again and if the voltage reading is greater than 1 volt clean the battery negative cable ends and battery post and negative cable to motorcycle frame or other grounding point, tighten same and similarly the starter mounting points and studs because there is a problem with the starter ground (could be looseness, corrosion, powder coat/paint problems etc). If the voltage reading is 1 volt or less than 1 volt in this test the ground circuit is okay and it will be necessary to perform a starter current draw test on the vehicle (and/or a starter current free draw test on the bench). If the results are within the specifications for the starter in these tests remove the spark plugs, raise the rear wheel so it can spin unimpeded, put the transmission in 5th gear and rotate the rear wheel to check for engine, transmission, primary and/or crankshaft resistance/bind. If the results are not within the amperage specifications for the particular starter replace or repair the starter motor to bring within the system amperage specifications.
8/31/2014 8:42:52 AM •
2004 Harley...
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Answered
on Aug 31, 2014
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89 views
Harley troubleshooting
If high beam element is not burned out it should light but you say when you have it on there is no headlight but then you say when you switch to high beam you have a headlight but it dims. You need to clarify what headlight beam you do or do not have and if the elements are okay it sounds like maybe you have a poor ground problem at the headlight.
8/29/2014 5:53:53 AM •
2004 Harley...
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Answered
on Aug 29, 2014
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612 views
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