Question about 1993 Harley Davidson XLH Sportster 883 Deluxe

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1991 harley sporster not charging, alternator?? is it repairable and where is it?

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Yes your Sportster has an alternator and it is replaceable. It is located behind the engine sprocket on the left side of the engine in the primary case.

First, let's make sure your alternator is bad. Using a DVOM (digital volt ohm meter) we'll test the entire system. You must have a fully charged battery in the bike to run this test. Connect the red meter lead to the positive post of your battery and the black meter lead to the negative. Put the function selector of the meter in DC VOLTS, 20 VOLTS or greater. Now, start the bike and bring the engine to a fast idle. The meter should read 14.5-15.0 volts. If not, test the alternator.

From the right side of the bike, look across the engine to the primary case just behind the rear cylinder for a wire coming out of the primary. It will have a round plug on it. Unplug the plug. Inside the plug on the primary side, you'll see two metal connectors. These are where we will test your alternator. Since we are testing AC current, it makes no difference which meter lead goes to which metal connector just make sure you're on the alternator side of the wire instead of the regulator side. Put your meter's function selector in AC VOLTS, 50 VOLTS or greater. Start the engine and bring it to high idle. Insert a meter probe into each of the metal connectors. Your meter should read 25 volts or higher.

If it does, your alternator is good and your regulator is the culprit causing your problems. The regulator is located on the frame downtubes just behind the front wheel.

If you want to repair your alternator, Disconnect the battery, drain the primary case and remove the cover. You'll have to take the compensator sprocket, the primary chain, and the clutch assembly off of the bike. Then remove the rotor and your stator is behind the rotor. Remove the stator and replace it with a new one. Reassemble the bike. If you need more specific instructions, please repost.

Good luck
Steve

Posted on Sep 10, 2010

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Hi Anonymous, perform the following tests:
1. Fill acid type batteries to proper levels.
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Hi Anonymous, perform the following tests:
1. Fill acid type batteries to proper levels.
2. Charge battery overnight at 1-2 amps you need 12.5 volts or better after charging.
3. Hook up battery positive cable, then with your multimeter on the milliamp scale connect one lead to the negative battery post and the other lead to the ground cable. Meter should read 3 milliamps or less, 10 milliamps with a radio, 15 milliamps with radio and CB. If your meter reads higher you need to isolate the circuit by pulling fuses and circuit breakers one at a time and observe meter for drop in aprerage then get out your test light and track down the short in that circuit.
3. Make sure all connections are clean and tight especially the negative cable at both ends.
4. Hook up volt meter to battery and start engine, if meter falls below 9.5 v while cranking replace battery.
5. With engine running at 3600 RPM battery should read 14.3-14.7 volts if not continue tests.
6. Unplug voltage regulator from alternator at crankcase by front of primary cover.
7. To test voltage regulator go to: https://www.youtube.com/watch?v=F8EjV0IjW9Q
8. With ohm meter, one lead grounded, touch alternator pin meter should read infinity, if not replace stator.
9. With ohm meter, both leads touching alternator pins meter should read 0.1 to 0.2 ohms on 1989 and later models. 0.2 to 0.4 ohms 1988 and earlier models, if not replace stator.
10. With volt meter set on AC scale, both leads touching alternator pins meter should read
16 to 20 volts AC for every 1000 RPM'S 1989 and later and 19 to 26 volts AC for every 1000 RPMS. If not replace rotor.
17. For a free wiring diagram please visit the website below and good luck.
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Hi Anonymous, could be for more information about your question please visit the websites below. Good luck and have nice day.
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