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.
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.
Sep 09, 2014 |
2004 Harley Davidson FLHTC - FLHTCI...