CHARGING SYSTEM TESTING
Battery: Turn ohmmeter to the DC Volts setting that can read 12V or more. With your motorcycle off, read from Positive to Negative making sure the Red is +, Black is -- If battery is good you should get about 12.5 to 13.5 volts
Charging: Using same multi-meter range, start the motorcycle and run RPM's up to above idle. Voltage should increase to several volts above initial reading, usually to about 14.7 V. Voltage should not go much higher than 14.7 V. If voltage goes a lot higher when you rev the engine, you could be overcharging due to a voltage regulator problem. If voltage doesn't change, your motorcycle is not charging.
Stator: If your motorcycle is not charging, you need to check the stator. Locate the plug for the stator on the front of the engine block. Switch the multi-meter to OHMS range on the lowest setting, usually 10 ohms. With the motorcycle off, read between the 2 pins or holes in the block. These should show continuity. If your meter is accurate you could read 1 to 3 ohms, but cheaper meters will not be that accurate. As long there is continuity it passes this test.
Now change the setting on the multi-meter to the highest OHM range like 100K. Touch one probe to a pin or hole in the engine, the other to the engine case or a metal bolt on the engine. The meter should not move. Try the other pin the same way and it also shouldn't move. If you get any reading the stator is shorted and must be replaced. This requires special tools and you should consider taking it to a shop. If you get no movement on the meter, it's not shorted out so you need to check for output.
To check for output, change multi-meter to AC Volts setting over 100 Volts. With the alternator plug disconnected, start the bike. Use the probes (not polarity sensitive) to read between the pins or holes in the engine block. You should read about 20V per 1000 rpm's. At idle expect about 25V, as you rev the engine it will increase to 60 or 70 Volts. If it does your stator is OK, if you get no output the stator is bad and you will need to replace it or take it to a shop.
Voltage Regulator: If your stator is not shorted to ground and has the proper output, your regulator is most likely the culprit. If your stator checks out OK but battery voltage don’t increase when the motorcycle is running, the regulator isn't doing its job and needs to be replaced. It's an easy swap; just make sure you bring the old one with you to make sure they give you the correct unit. If the battery voltage goes too high when you rev the motorcycle the regulator isn't limiting the voltage and again it needs replacement.
