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techtalk:evo:elec01 [2023/04/28 05:31]
ixl2relax [Battery Voltage Readings]
techtalk:evo:elec01 [2024/01/02 22:42] (current)
hippysmack
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   * From Keyswitch to Starter Relay   * From Keyswitch to Starter Relay
   * Output of Starter Relay to Starter Solenoid   * Output of Starter Relay to Starter Solenoid
-  * Output of Voltage Regulator to Main Circuit Breaker ((http://​xlforum.net/​forums/showthread.php?​t=2022873))+  * Output of Voltage Regulator to Main Circuit Breaker ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​189707-stator-regulator-wire-gauge?​t=2022873))
  
  
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   * Main 50a CB to Keyswitch   * Main 50a CB to Keyswitch
  
-In a [[http://​xlforum.net/​forums/showthread.php?​t=1506137|thread by morvenhouse on the XLForum]], he included this picture of the difference between his 6-AWG stock battery cable and the 3-AWG battery cable he made: +In a [[https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​138767-an-electric-starter-guide?​t=1506137|thread by morvenhouse on the XLForum]], he included this picture of the difference between his 6-AWG stock battery cable and the 3-AWG battery cable he made: 
-{{:​techtalk:​evo:​elec:​batterycable-3awg-morvenhouse.jpg|}}((http://​xlforum.net/​forums/showthread.php?t=1506137 - Pic from morvenhouse - Annotated by IXL2Relax))+{{:​techtalk:​evo:​elec:​batterycable-3awg-morvenhouse.jpg|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​138767-an-electric-starter-guide?t=1506137 - Pic from morvenhouse - Annotated by IXL2Relax))
  
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 **[[https://​www.rbracing-rsr.com/​wiring_ecu.html#​supplies|Here is a link]]** to a great listing of connector and connection options. That web page discusses switches, wiring, connectors and tools. **[[https://​www.rbracing-rsr.com/​wiring_ecu.html#​supplies|Here is a link]]** to a great listing of connector and connection options. That web page discusses switches, wiring, connectors and tools.
-Contributed by Oldrump1 from the XLForum.net ((http://​xlforum.net/​forums/showthread.php?​threadid=1979596))+Contributed by Oldrump1 from the XLForum.net ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-lighting/​184283-diy-wiring?​threadid=1979596))
  
 **Deutsch Connectors** **Deutsch Connectors**
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-Here's an [[http://​xlforum.net/​forums/showthread.php?​t=727971|XLForum Thread]] that shows **how to disassemble various connectors**.+Here's an [[https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​90139-connector-removal-how-to?​t=727971|XLForum Thread]] that shows **how to disassemble various connectors**.
  
 For Multi-Lock Connectors, here's an animation of Removing the Wire From the Connector:​\\ For Multi-Lock Connectors, here's an animation of Removing the Wire From the Connector:​\\
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 The large Negative Battery Cable on the early models went to rear motor mount. Later, it was moved to the backside of the Primary cavity on the crankcase near the Starter Motor. The large Negative Battery Cable on the early models went to rear motor mount. Later, it was moved to the backside of the Primary cavity on the crankcase near the Starter Motor.
  
-"I was checking the voltage at the battery against the voltage at the starter, at first it was the same. I moved the bike to get to the other side and double checked the voltage and it dropped significantly. I nudge the battery once and watched the voltage go to zero! I removed the positive lead and it appeared fine on the outside. One good pull on both ends and the end to the starter and about 2" of copper strands slid out from the insulating jacketing",​ said TimC of the XLForum.((http://​xlforum.net/​forums/showthread.php?​t=1513037))+"I was checking the voltage at the battery against the voltage at the starter, at first it was the same. I moved the bike to get to the other side and double checked the voltage and it dropped significantly. I nudge the battery once and watched the voltage go to zero! I removed the positive lead and it appeared fine on the outside. One good pull on both ends and the end to the starter and about 2" of copper strands slid out from the insulating jacketing",​ said TimC of the XLForum.((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​139448-1200s-check-engine-sputter-backfire?​t=1513037))
  
 **To check the battery cables** - PULL HARD on both ends of both the positive and the negative cables where they mount to the battery and to the engine. There should be no looseness to the cable at the connector junction. Corrosion in the connectors and the wire itself can be hidden from your casual examination yet will still cause severe loss in current capability. Therefore, PULL HARD to be sure they are solid. **To check the battery cables** - PULL HARD on both ends of both the positive and the negative cables where they mount to the battery and to the engine. There should be no looseness to the cable at the connector junction. Corrosion in the connectors and the wire itself can be hidden from your casual examination yet will still cause severe loss in current capability. Therefore, PULL HARD to be sure they are solid.
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 Then use your voltmeter (multimeter,​​ dvm, etc.) to measure the incoming voltage (from the battery) at the key switch. Then measure the outgoing voltage from each of the keyswitch positions. If you still have no power, continue checking downstream, thru the fuses, until you find the break in the voltage circuit. Then use your voltmeter (multimeter,​​ dvm, etc.) to measure the incoming voltage (from the battery) at the key switch. Then measure the outgoing voltage from each of the keyswitch positions. If you still have no power, continue checking downstream, thru the fuses, until you find the break in the voltage circuit.
  
-{{:​techtalk:​evo:​elec:​BatteryPost-Melted-Arcing-TheDoctor71.jpg?​600|}}((http://​xlforum.net/​forums/showthread.php?t=2071578 - Pic from The Doctor71 - Annotated by IXL2Relax)) {{:​techtalk:​evo:​elec:​batterypost-ziptie-sportsterpaul.jpg?​280|}}((Pic from SportsterPaul))\\+{{:​techtalk:​evo:​elec:​BatteryPost-Melted-Arcing-TheDoctor71.jpg?​600|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​195261-why-tight-battery-cables-are-important?t=2071578 - Pic from The Doctor71 - Annotated by IXL2Relax)) {{:​techtalk:​evo:​elec:​batterypost-ziptie-sportsterpaul.jpg?​280|}}((Pic from SportsterPaul))\\
  
 As you can see in the pictures above, if the connections are not tight even the posts can melt due to high current arcing. The operational vibrations often loosen bolts of all sorts on the bike, including the battery cables. In addition to tightening the bolts, you can physically restrain the connectors with a zip tie around the battery post. With proper placement, even the rubber boots can be put back in place. As you can see in the pictures above, if the connections are not tight even the posts can melt due to high current arcing. The operational vibrations often loosen bolts of all sorts on the bike, including the battery cables. In addition to tightening the bolts, you can physically restrain the connectors with a zip tie around the battery post. With proper placement, even the rubber boots can be put back in place.
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 ===== Battery Voltage Readings ===== ===== Battery Voltage Readings =====
-From the XLForum.net ((from sportsterdoc of the XLFOUM ​http://​xlforum.net/​forums/showthread.php?t=1784651 with slight modifications))+From the XLForum.net ((from sportsterdoc of the XLFOUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​166144-voltage-readings-why-we-need-them?t=1784651 with slight modifications))
  
 Whenever there is a problem that may even remotely be electrical, it is important to know the quality of power with which you are operating. This is why you should have a volt-ohm meter (DVM/​Multimeter) and take voltage readings, as described below, as part of your initial diagnostics. Whenever there is a problem that may even remotely be electrical, it is important to know the quality of power with which you are operating. This is why you should have a volt-ohm meter (DVM/​Multimeter) and take voltage readings, as described below, as part of your initial diagnostics.
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 There could be as many as a dozen points on the frame used for grounding other devices. The front turn signals (on the handlebars) were grounded thru a connecting strap between the fork riser bolts & the triple tree. There could be as many as a dozen points on the frame used for grounding other devices. The front turn signals (on the handlebars) were grounded thru a connecting strap between the fork riser bolts & the triple tree.
  
-{{:​techtalk:​evo:​elec:​86-93-handlebarground.jpg?​500|}}{{:​techtalk:​evo:​elec:​86-93-devicegrounds.jpg?​250|}}((http://​xlforum.net/​forums/showthread.php?t=2073777 - Pics from John Harper - Annotated by IXL2Relax))+{{:​techtalk:​evo:​elec:​86-93-handlebarground.jpg?​500|}}{{:​techtalk:​evo:​elec:​86-93-devicegrounds.jpg?​250|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​197175-1991-frame-engine-original-ground-locations?t=2073777 - Pics from John Harper - Annotated by IXL2Relax))
  
 **Beginning in 1994**, the wiring harness itself began to carry ground wires to various components. The wiring harness by then consisted of many separate power wires to multiple locations, with a number of circuit breakers protecting the various circuits from overload. **Beginning in 1994**, the wiring harness itself began to carry ground wires to various components. The wiring harness by then consisted of many separate power wires to multiple locations, with a number of circuit breakers protecting the various circuits from overload.
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 **The battery ground cable and the common wiring harness ground wires connect to the engine**. Up through 2003, the ground wires connected onto the upper left (or right) rear engine mounting bolt. After the bolt & nut secured the engine to the frame, the battery & harness cables are placed onto the extended bolt and a lock nut is then used on the same bolt - this secures the cables to the engine & frame. There were still devices that grounded thru the frame (back to the battery), such as the horn, the oil pressure indicator switch and the neutral indicator switch. **The battery ground cable and the common wiring harness ground wires connect to the engine**. Up through 2003, the ground wires connected onto the upper left (or right) rear engine mounting bolt. After the bolt & nut secured the engine to the frame, the battery & harness cables are placed onto the extended bolt and a lock nut is then used on the same bolt - this secures the cables to the engine & frame. There were still devices that grounded thru the frame (back to the battery), such as the horn, the oil pressure indicator switch and the neutral indicator switch.
  
-{{:​techtalk:​evo:​elec:​harnessgrounds-86-03-decman.jpg?​600|}}((http://​xlforum.net/​forums/showthread.php?t=1944256 - Pic from decman - Annotated by IXL2Relax))\\+{{:​techtalk:​evo:​elec:​harnessgrounds-86-03-decman.jpg?​600|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​180689-looking-for-a-pic?t=1944256 - Pic from decman - Annotated by IXL2Relax))\\
  
 **Beginning in 2004**, the Rubbermount models have the wiring harness grounds collected to a single point on the engine called the **Powertrain Ground Point**. Located near the starter motor, this PGP is a dual-threaded stud mounted horizontally to the engine case with the ground wires from the wiring harness attached by a nut. **Beginning in 2004**, the Rubbermount models have the wiring harness grounds collected to a single point on the engine called the **Powertrain Ground Point**. Located near the starter motor, this PGP is a dual-threaded stud mounted horizontally to the engine case with the ground wires from the wiring harness attached by a nut.
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-Here is a link to a very long [[http://​xlforum.net/​forums/showthread.php?​t=1891463|XLForum Thread]] about corrosion in the threads of the Engine Ground bolt (might be used for Powertrain Ground Point or Battery Negative cable depending on year). That corrosion degraded the voltage to the engine significantly. Also, more reading [[http://​xlforum.net/​forums/showthread.php?​t=463372|HERE]] regarding battery cables.+Here is a link to a very long [[https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​176231-nightster-electrical-problems-not-sure-where-to-go-from-here?​t=1891463|XLForum Thread]] about corrosion in the threads of the Engine Ground bolt (might be used for Powertrain Ground Point or Battery Negative cable depending on year). That corrosion degraded the voltage to the engine significantly. Also, more reading [[https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​69147-starter-hesitation-read-this-first?​t=463372|HERE]] regarding battery cables.
  
 2004-later has two main ground points - Engine Case Battery Ground & Power Train Ground (AKA GND1)\\ 2004-later has two main ground points - Engine Case Battery Ground & Power Train Ground (AKA GND1)\\
 (2004-2007 may have these reversed with battery ground on primary cover & harness ground on case stud)\\ (2004-2007 may have these reversed with battery ground on primary cover & harness ground on case stud)\\
-{{techtalk:​evo:​elec:​04-later-groundpoints.jpg?​600|}}((http://​xlforum.net/​forums/showthread.php?t=1891463 - Pic from Chopsticks - Annotated by IXL2Relax))\\+{{techtalk:​evo:​elec:​04-later-groundpoints.jpg?​600|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​176231-nightster-electrical-problems-not-sure-where-to-go-from-here?t=1891463 - Pic from Chopsticks - Annotated by IXL2Relax))\\
  
 There is an Engine-to-Frame Grounding Strap under the rear of the engine\\ There is an Engine-to-Frame Grounding Strap under the rear of the engine\\
-{{techtalk:​evo:​elec:​04-rear-grounding-strap.jpg?​600|}}((http://​xlforum.net/​forums/showthread.php?t=1891463 - Pic from Chopsticks - Annotated by IXL2Relax))+{{techtalk:​evo:​elec:​04-rear-grounding-strap.jpg?​600|}}((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-electrical/​sportster-motorcycle-electrical-and-ignition/​176231-nightster-electrical-problems-not-sure-where-to-go-from-here?t=1891463 - Pic from Chopsticks - Annotated by IXL2Relax))
  
 ===== Testing for Proper Grounds ===== ===== Testing for Proper Grounds =====