Testing Current Control Unit Setting On 3 Unit Regulators

Use same connections as previous Test E, Voltage Control Test. (See Fig. 51-10).

1. Turn field control to "Direct" position.

2. Operate engine at 2000 RPM.

3. Turn load control clockwise until maximum reading is obtained on ammeter.

This reading will be equal to the current limiter setting. If not within specifications (see Fig. 51-1), replace or adjust according to manufacturer's Service Bulletin and retest. Take final reading with regulator cover in place.

Figure 51-11.

GENERATOR SYSTEM WITHOUT BATTERY (6 VOLT)

Covers 1964 and earlier Sportster Model XL CH

A. TESTER CONTROLS

Turn ground polarity selector to Negative; load control knob to Direct: ammeter selector to 100A position; and voltage selector to 6 volt position.

B. TESTER CONNECTIONS (See Fig. 51-11)

1. Remove wires from regulator "BAT" terminal.

2. Connect Regulator lead "R" of tester to regular "BAT" terminal.

3. Connect Ground lead "G" of tester to ground on motorcycle.

4. Connect Positive lead of voltmeter to regulator "GEN" terminal.

5. Connect Negative lead of voltmeter to ground on motorcycle.

6. Remove wire connected to regulator "F" terminal and connect this wire to a lead of the field control variable resistor. Connect other lead of field control to ground on motorcycle. Turn field control variable resistor to "Direct" position.

Battery lead "B" of tester is not connected.

C. TESTING GENERATING SYSTEM

1. Operate engine at 2700 RPM (approximately 45 MPH).

2. Turn load control clockwise until a 15 ampere reading is observed.

If reading is 15 amperes or more, generator is not at fault and difficulty is in voltage regulator. Make Tests D, E and F.

If no ammeter reading is obtained or reading is low, observe voltmeter reading. If reading is below 6 volts, generator requires service. If voltmeter reading is high (over 7.5 volts), the cutout relay is not closing. Make Test D following.

D. TESTING CUTOUT RE LAY UNIT CLOSING VOLTAGE (Fig. 51-11)

1. Connect battery lead "B" of tester to 1-1/2 ohm connection on side of tester.

2. Turn field control variable resistor to "Open" position.

3. Turn load control knob to "Direct" position.

4. Operate engine at approximately 2000 RPM (35 MPH).

5. Slowly turn field control knob toward the "Direct" position to decrease resistance in generator field circuit. As the resistance is decreased, voltmeter reading will increase until a kickback of the voltmeter needle is observed. The highest voltage noted will be the cutout relay closing voltage. Repeat operation several times, each time turning the field control to "Open" position. If the closing voltage is not within specifications (see Fig. 51-1), adjust according to manufacturer's Service Bulletin and retest.

Figure 51-12.

E. TESTING VOLTAGE CONTROL UNIT SETTING (FIG. 51-12)

1. Move positive voltmeter lead to regulator "BAT" terminal.

2. Move field control lead from ground on motorcycle to regulator field terminal.

3. Turn field control variable resistor to "Direct" position.

4. Operate engine at 2700 RPM, (approximately 45 MPH).

5. Turn field control variable resistor to "Open" position, then to "Direct" to cycle regulator. Observe voltmeter reading.

6. If voltmeter reading is not within specifications (see 51-1), replace or adjust regulator according to manufacturer's Service Bulletin.

METHOD il TESTING bosch regulators

(VAT 26 TESTER)

12 VOLT SYSTEM WITH OR WITHOUT BATTERY Covers 1965 Sportster Models XLH and XLCH

A. TESTER CONTROLS

Turn ground polarity selector to Negative; load control knob to Direct; ammeter selector to 100A position; and voltage selector to 12 volt position.

B. TESTER CONNECTIONS (SEE FIG. 51-13)

1. Remove wires from regulator "B+" terminal. On XLH models, connect these wires together.

2. Connect Regulator lead "R" of tester to regulator terminal "B+".

3. Connect Ground lead "G" of tester to ground on motorcycle.

4. Connect Positive voltmeter lead to regulator terminal "D+" and connnect Negative lead to ground on motorcycle.

5. Remove wire from regulator terminal "DF" and connect this wire to a lead of the field control variable resistor. Connect the other lead of the field control to ground on motorcycle. Turn field control to "Direct" position. Turn load control to "Direct" position.

Battery lead "B" of tester is not connected for this test.

C. TESTING GENERATING SYSTEM

1. Operate engine at 2700 RPM (approximately 45 MPH).

2. Slowly rotate load control clockwise until a reading of 10 amperes is observed.

3. If a reading of 10 amperes is obtained, generator is not at fault and difficulty is due to a faulty regulator or defective wiring. Inspect wiring and make Tests D and E.

4. If a reading of 10 amperes cannot be obtained and voltmeter reading is below 12 volts, generator is defective.

5. If no reading is obtained on ammeter but voltmeter reading is 15 volts or higher, cutout relay is defective. Regulator should be replaced and circuit retested.

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