RECTIFIER /REGULATOR
NOTE :
If vehicle is equipped with single phase rectifier/ regulator, complete the steps described, but omit the references made to the third wire (three phase rectifier/regulator).
Dynamic Test
1. Set multi-meter to DCV or Vdc (DC volts); switch the range to 20 or 50V. Connect the multi meter leads to the battery terminals. Start and rev the engine up to 3000 r/min. Check the battery voltage.
2. If the voltage is higher than 13.5V, rev the engine to 5000 r/min. Check the reading on the meter, if it is lower than 14.8V, the charging system is OK.
3. If the voltage at 3000 r/min. is lower than 13.5V, go to the static test.
Static Test
1. Disconnect the rectifier/regulator from the vehicle wiring harness.
2. Switch the multi meter to Ohms (lowest range).
3. If the rectifier regulator has two red output wires and two black output wires:
Test for continuity between both black wires; there should be continuity.
Test for continuity between both red wires; there should be continuity.
Test for short circuit between one of the red wires and the two blacks; there should be no continuity. Repeat the test for the other red wire. There should be no continuity.
Test for continuity between both black output wires and the rectifier/regulator housing. There should be no continuity.
4. Connect the positive multi meter probe to the red output wire of the rectifier/regulator. Connect the black multi meter to the yellow input wire. Repeat this procedure for each wire.
If an OL (no continuity) is indicated in all three yellow wires, go to the next step.
If you have continuity on any of the three yellow wires, replace the rectifier/regulator with a new one.
5. Connect the negative multi meter probe to the red output wire of the rectifier/regulator. Connect the positive probe to a yellow input wire. Check the reading. Repeat the test for each wire.
If a reading around 1 to 1.5 Ohms is obtained on all wires, go to the next step.
If an OL (no continuity) is obtained on any wire, replace the rectifier/regulator with a new one.
6. Connect the negative multi meter probe to the negative output wire of the rectifier/regulator. Connect the positive multi meter probe to one yellow wire. Check the reading. Repeat for all yellow wires.
If an OL (no continuity) is on all three wires is obtained, go to the next step.
If you have continuity on any wire, replace the rectifier/regulator with a new one.
7. Connect the positive multi meter probe to the negative output wire of the rectifier/regulator. Connect the negative multi meter probe to one yellow wire and check the reading. Repeat for the other two yellow wires.
If a reading around 1 to 1.5 Ohms is obtained on all three tests, the rectifier/regulator is OK.
If an OL (no continuity) is obtained on any one of the three tests, replace the rectifier/regulator.
Electrical Component Troubleshooting
Stator
Stator
NOTE :If vehicle is equipped with a single phase stator, complete the steps described, but omit the references made to the third wire (three phase stator).
Static Test
1. Disconnect the stator connector.
2. Set multi meter to the lowest Ohms setting. Measure the resistance between all three wires coming from the stator. Start with one wire and read resistance between it and the other two. Repeat for remaining two wires.
If all readings are within 0.5 to 2.0 Ohms, go to the next step.
If one of the readings is lower than 0.5 Ohms or higher than 2.0 Ohms, replace the stator.
3. Connect one of the multi meter leads up to one of the three yellow wires. Connect the other multi meter lead up to the crankcase or to a grounding point on stator core if it has been removed. Check the reading on the meter. Make sure the connection of the lead to the crankcase or stator core is a good one.
No reading or ????????????????OL??????????????? displayed, go to the next step.
If you have any reading between 100 Ohms and zero Ohms, replace the stator.
Dynamic Test - AC Output
1. Switch the multi meter to the AC voltage (range at least 100 VAC). Make sure you do not switch to DCV or Vdc by mistake. Connect the multi meter leads between two of the yellow wires emerging from the stator. Start the engine and bring to 5000 r/min. Check the reading on the meter. Switch one of the multi meter leads to another yellow wire and check the reading again.
If three equal readings are obtained, all higher than 50 VAC, the stator is ok. A problem may exist in the rectifier/regulator. Test the rectifier/ regulator.
NOTE :If vehicle is equipped with a single phase stator, complete the steps described, but omit the references made to the third wire (three phase stator).
Static Test
1. Disconnect the stator connector.
2. Set multi meter to the lowest Ohms setting. Measure the resistance between all three wires coming from the stator. Start with one wire and read resistance between it and the other two. Repeat for remaining two wires.
If all readings are within 0.5 to 2.0 Ohms, go to the next step.
If one of the readings is lower than 0.5 Ohms or higher than 2.0 Ohms, replace the stator.
3. Connect one of the multi meter leads up to one of the three yellow wires. Connect the other multi meter lead up to the crankcase or to a grounding point on stator core if it has been removed. Check the reading on the meter. Make sure the connection of the lead to the crankcase or stator core is a good one.
No reading or ????????????????OL??????????????? displayed, go to the next step.
If you have any reading between 100 Ohms and zero Ohms, replace the stator.
Dynamic Test - AC Output
1. Switch the multi meter to the AC voltage (range at least 100 VAC). Make sure you do not switch to DCV or Vdc by mistake. Connect the multi meter leads between two of the yellow wires emerging from the stator. Start the engine and bring to 5000 r/min. Check the reading on the meter. Switch one of the multi meter leads to another yellow wire and check the reading again.
If three equal readings are obtained, all higher than 50 VAC, the stator is ok. A problem may exist in the rectifier/regulator. Test the rectifier/ regulator.
Flywheel
Inspection Points
1. Check for contact between the installed flywheel and crankshaft position sensor. Make sure the specified sensor air gap is maintained throughout flywheel rotation.
SERVICE:
1. Inspect the flywheel for cracking, damaged magnetic material, key groove, and woodruff (crankshaft) key.
2. Check flywheel key location. Make sure the hub has not spun in the aluminum body. The key ????????????????cut??????????????? in the hub should be aligned with the ????????????????C??????????????? in the molded ????????????????Cannondale??????????????? text.
1. Check for contact between the installed flywheel and crankshaft position sensor. Make sure the specified sensor air gap is maintained throughout flywheel rotation.
SERVICE:
1. Inspect the flywheel for cracking, damaged magnetic material, key groove, and woodruff (crankshaft) key.
2. Check flywheel key location. Make sure the hub has not spun in the aluminum body. The key ????????????????cut??????????????? in the hub should be aligned with the ????????????????C??????????????? in the molded ????????????????Cannondale??????????????? text.
Soleniod
Dynamic Test - Solenoid Function
1. Press the engine start button. On ATVs, the additional step of turning the ignition key ON and pulling in the clutch lever is required before pressing the start button.
The solenoid is normal if the solenoid clicks when the start button is pressed.
If you do not hear a ????????????????CLICK???????????????, go to the next test.
Static Test -Harness Voltage
1. Disconnect the solenoid from the main wiring harness.
2. On ATVs, turn the ignition key ON and pull in the clutch lever.
Set multi meter to DCV 20V range and connect the positive meter lead to connector pin A; connect the negative meter lead to connector pin B. Press the engine start button. The reading should be same as battery voltage (12.5 to 13.0Vdc).
If no voltage is detected, check the main fuse.
If the main fuse is OK, check the starting circuit for an open or short circuit. Take corrective action. Consult the vehicle wiring diagram.
3. Set multi meter to Ohms. Connect the positive meter lead to solenoid connector harness pin B and the negative meter lead to ground. There should be continuity.
If an open circuit is detected, consult the vehicle wiring diagram.
Static Test -Resistance
1. Disconnect the solenoid from the main wiring harness.
2. Measure the resistance of the solenoid coil at the harness connector.
SERVICE: Solenoid coil resistance 5.0 Ohm
Operation Test harness starting circuits for short or open circuits.
1. Disconnect the solenoid from the main wiring harness.
2. Connect the positive lead of a 12V battery power source to the solenoid coil positive lead or terminal (pin A) and the negative lead of the 12V battery power source to the solenoid coil negative lead or terminal (pin
.
There should be continuity between the large terminals while the battery source is connected, and no continuity when the battery source is disconnected
1. Press the engine start button. On ATVs, the additional step of turning the ignition key ON and pulling in the clutch lever is required before pressing the start button.
The solenoid is normal if the solenoid clicks when the start button is pressed.
If you do not hear a ????????????????CLICK???????????????, go to the next test.
Static Test -Harness Voltage
1. Disconnect the solenoid from the main wiring harness.
2. On ATVs, turn the ignition key ON and pull in the clutch lever.
Set multi meter to DCV 20V range and connect the positive meter lead to connector pin A; connect the negative meter lead to connector pin B. Press the engine start button. The reading should be same as battery voltage (12.5 to 13.0Vdc).
If no voltage is detected, check the main fuse.
If the main fuse is OK, check the starting circuit for an open or short circuit. Take corrective action. Consult the vehicle wiring diagram.
3. Set multi meter to Ohms. Connect the positive meter lead to solenoid connector harness pin B and the negative meter lead to ground. There should be continuity.
If an open circuit is detected, consult the vehicle wiring diagram.
Static Test -Resistance
1. Disconnect the solenoid from the main wiring harness.
2. Measure the resistance of the solenoid coil at the harness connector.
SERVICE: Solenoid coil resistance 5.0 Ohm
Operation Test harness starting circuits for short or open circuits.
1. Disconnect the solenoid from the main wiring harness.
2. Connect the positive lead of a 12V battery power source to the solenoid coil positive lead or terminal (pin A) and the negative lead of the 12V battery power source to the solenoid coil negative lead or terminal (pin
. There should be continuity between the large terminals while the battery source is connected, and no continuity when the battery source is disconnected
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cannondale27
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