ELECTRICAL
5.8
CHARGING SYSTEM TESTING
Whenever charging system problems are suspected,
proceed with the following system check.
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
below the “Break Even” RPM. Con-
tinued problems would call for battery
inspection.
Disconnect the Yellow/Red, White, and Red
wires from the regulator/rectifier. Using a
multitester, perform an Alternator Output
(AC amp) test. See test procedure on
page 5.9 for procedure.
Is output above 5 amps?
Inspect the wiring harness be-
tween the panel and the stator for
damage. If no damage is found,
remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
tor coils and stator wire harness
for damage. Repair or replace
any damaged components.
Reconnect the alternator wires. Battery volt-
age must be present on red wire terminal on
harness side of voltage regulator connector.
Is it?
Check regulator/rectifier connections
and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
If all of the previous tests indicate a
good condition, but the charging voltage
does not rise above battery voltage at the
connector , replace the voltage regulator.
No
Yes
No
Yes
Perform system “Break Even Amperage”
test outlined on Page 5.9.
Does charging occur as specified?
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (See
Page 5.5). It should be 12.5 volts or more.
Is it?
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
or a fully charged shop battery.
With the drive wheels securely off the ground,
start the engine and increase RPM to between
3000 and 4000. Read battery voltage with the
multitester. Readings should increase to be-
tween 13.0 and 14.6 V D.C. Are they?
No
Yes
No
Yes
Check Key off Current Draw
No
Meter Setting: AC Amps
Meter Setting: DC Amps
Meter Setting: DC Volts
Meter Setting: DC Volts
Yes
Should between .1 and .2 volts
Ohm stator wire (W/YR) If bad replace, if good,
continue with alternator output test.
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Summary of Contents for Sportsman 90
Page 1: ...SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 SERVICE MANUAL PN 9918068 The Way Out ...
Page 8: ...GENERAL INFORMATION 1 4 ...
Page 28: ......
Page 68: ...FUEL SYSTEM CARBURETION 3 14 NOTES ...
Page 84: ...BODY STEERING SUSPENSION 4 16 NOTES ...
Page 102: ...ELECTRICAL 5 18 SCRAMBLER 50 WIRING DIAGRAM Scrambler 50 ...
Page 108: ......
Page 109: ...PN 9918068 Printed in USA ...