Service manual

ELECTRICAL
CURRENT DRAW - KEY OFF
Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to
light bulbs and speed limiter.
Connect an ammeter in series with the negative battery
cable. Check for current draw with the key off.
If the draw is excessive, loads should be disconnected
from the system one by one until the draw is eliminated.
Check component wiring as well as the component for
partial shorts to ground to eliminate the draw.
Current Draw - Key Off:
Maximum of .02 DCA (20 mA)
Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to
light bulbs and speed limiter.
The “break even” point of the charging system is the
point at which the alternator overcomes all system loads
(lights, etc.) and begins to charge the battery.
Depending on battery condition and system load, the
break even point may vary slightly. The battery should be
fully charged before performing this test.
◎ Clamp an inductive ammeter or connect an ammeter
(set to DC amps) in series between the negative battery
cable and terminal.
◎ Connect a tachometer according to manufacturer’s
instructions.
◎ With engine off and the key and kill switch in the
ON position, the ammeter should read negative amps
(battery discharge). Reverse meter leads if a positive
reading is indicated.
◎ Shift transmission into neutral and start the engine. If
using an ammeter in series, start engine with kick
start only.
◎ Turn headlight on high beam and apply the brake
light. Increase engine RPM while observing ammeter and
tachometer.
◎ Note RPM at which the battery starts to charge
(ammeter indication is positive).
◎ With lights and other electrical load off, this should
occur at approximately 1500 RPM or lower.
◎ Turn the lights on and lock parking brake to keep
brake light on.
◎ Repeat test, observing ammeter and tachometer. With
lights on, charging should occur at or below 2000 RPM.
ALTERNATOR OUTPUT TEST (AC AMP)
This test measures AC amperage from the alternator.
This test simulates a “full load” on the alternator.
Do not perform this test longer than required to
obtain a reading or the alternator stator windings
may overheat. Do not exceed idle rpm during this test.
To Calculate Available Alternator Output
I=P/E, 150W / 12V = 12.5 Amps I =
I = Current in Amps
P = Power in Watts
E = Electromotive Force (Volts)
Alternator Current Output:
Minimum of 5 AC Amps
◎ Maximum alternator output will be indicated on the
meter. It is not necessary to increase engine RPM above
idle.
◎ Place the red lead on the tester in the 10A jack.
◎ Turn the selector dial to the AC amps position.
◎ Connect the meter leads to the wires leading
from the alternator (see schematic for proper wiring
colors).
◎
Start the engine and let it idle. Reading should
b
e
a minimum of 5A at idle.
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