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2006 Dyna: Starting & Charging 1-11
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DIAGNOSTICS/TROUBLESHOOTING 1.4

GENERAL NOTE
Open circuits on the ground side will read zero.
The troubleshooting tables beginning on page 1-1 contain 6. Typically, a good circuit will drop less than 1 volt.
detailed procedures to solve and correct problems. Follow the 7. If the voltage drop is greater, back track through the con-
1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose nections until the source of the potential difference is
starting system problems. The VOLTAGE DROPS procedure found. The benefit of doing it this way is speed and accu-
below will help you to locate poor connections or components racy.
with excessive voltage drops.
a. Readings aren’t as sensitive to real battery voltage.
b. Readings show the actual voltage dropped, not just
VOLTAGE DROPS the presence of voltage.
c. This tests the system as it is actually being used. It
Check the integrity of all wiring, switches, fuses and connec-
is more accurate and will display hard to find poor
tors between the source and destination.
connections.
The voltage drop test measures the difference in potential or the d. This approach can be used on lighting circuits, igni-
actual voltage dropped between the source and destination. tion circuits, etc. Start from most positive and go to
most negative (the destination or component).
1. See ITEM A in Figure 1-2. Attach your red meter lead to
the most positive part of the circuit, which in this case 8. See ITEM D in Figure 1-2. The negative or ground circuit
would be the positive post of the battery (5). can be checked as well.
2. See ITEM B in Figure 1-2. Attach the black meter lead to a. Place the negative lead on the most negative part of
the final destination or component in the circuit (solenoid the circuit (or the negative battery post). Remember,
terminal from relay). there is nothing more negative than the negative
post of the battery.
3. Activate the starter and observe the meter reading. The
meter will read the voltage dropped or the difference in b. Place the positive lead to the ground you wish to
potential between the source and destination. check.
4. An ideal circuit’s voltage drop would be 0 volts or no volt- c. Activate the circuit. This will allow you to read the
age dropped, meaning no difference in potential. potential difference or voltage dropped on the nega-
tive or ground circuit. This technique is very effective
5. See ITEM C in Figure 1-2. An open circuit should read
for identifying poor grounds due to powdered paint.
12 volts, displaying all the voltage dropped, and the
Even the slightest connection may cause an ohm-
entire difference in potential displayed on the meter.
meter to give a good reading. However, when suffi-
cient current is passed through, the resistance
caused by the powdered paint will cause a voltage
drop or potential difference in the ground circuit.

2006 Dyna: Starting & Charging 1-9
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Starter Testing 5: Starter Spins, But Does Not Engage

Remove starter. Disassemble drive housing
assembly. Inspect for damage to armature
gear or idler gear. Damage present?

YES NO

Replace starter assembly. Starter clutch failure.
Replace starter clutch.

5825 5837

Starter Testing 6: Starter Stalls or Spins Too Slowly

Perform voltage drop tests from battery
1 positive to starter motor terminal. Crank
engine. Is voltage drop greater than 1 volt?

YES NO

Perform voltage drop tests Perform voltage drop tests between bat-
1 between battery positive to tery negative and starter studs or bolts.
starter battery terminal. Is voltage drop greater than 1 volt?
Crank engine. Is voltage drop
greater than 1 volt?

YES NO YES NO

Repair connection Repair or replace Clean ground Perform starter motor current
6
between battery and solenoid (contacts). connections. draw test (on vehicle).
starter.
5835
5845 Perform starter motor free draw
7
5824 bench test.

Are test results within range?

YES NO

Remove spark plugs while in Replace starter
5th gear. Rotate rear wheel. motor.
Check for engine, primary
and/or crankshaft bind. 5817

Use appropriate diagnostic trouble code