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Dead battery

Tuesday

Tuesday

Well-known member
Premium Member
07 800x with e-start (came with it). Dont have alot of experience with e-start and batteries on a sled set up. The battery and estart have never missed a beat in 500 miles (700 total on sled) and on the last ride the battery felt like it was continuely getting weaker with each start. Conditions where deep pow and mostly WOT. Havent changed anything recently on sled so nothing should be disconnected. Gave the sled a general look over and have yet to have time to closely look at any obvious reasons as to why the battery was not charging. All wires where connected and the fuse at the battery looked good.

Rode it one day with the dead battery and a couple of times I hit the start to see if it had been charging and it would start but appeared to be dragging. Basically doesnt appear to be charging while riding?

Anyone have a diagnosis or wiring diagram?

Later
 
Are your headlights still strong? If so, then your charging system is OK. You should be able to throw a multimeter on it to test the charge. Probably just a weak battery is my guess.
 
I have a similar problem only I am running a light weight version. After a few rides I throw a 2amp charger on it and it doesn't miss a beat. Not sure why it doesn't charge it back up--unless its so cold and so weak it won't take a charge??? It's never a problem in the spring when it's warmer.
 
Put the charger on and the battery is back on track will do some further testing to see why it was not taking charge while riding.

Yes, the headlights where running strong as well as the handwarmers.

However for some reason the battery was not charging.

later
 
Ok finally did some testing. Battery was only at 11.6 volts after using charger. Fired up the sled and there doesnt appear to be any extra voltage going through the battery once running. At revs what would be a normal about of voltage expected at battery? 13.5? I would assume more then 12v so that the battery would be charging as riding?

Second not really sure what to check back from the postive post in order to find the problem. There are alot of wires/selenoids etc. As mentioned I dont see any thing obvious disconnected and the fuse at the battery looks fine.

later
 
if the lights and hand warmers are working ok, I assume the stators output is ok. From there, that output goes to a voltage regulator/rectifier to make dc current, for the battery. I'm going to guess, that your problem lies there. Look for a multiwire component, with a heat sink. You will be able to measure it's input and output, and go from there. Take a pic, if you can, and post it.
 
Finally.

Charger was putting 12.6 volts across battery. After disconnecting charger voltage was 12.5 volts at the battery. When I hit the start voltage drops to approx 11.3ish and once it fires up voltage would jump back to 12.3 and slowly creep to 12.39. When I shut the sled off voltage would hover around 12.42 range. I started it about 6-7 times and voltage appeared to stay around that 12.4 mark. I still dont get the feeling that it is charging while running. If when sled is off and voltage is 12.4 I would expect voltage to be higher; like 12.6 (same as the charger) when its running? Anyway the fuse looks fine and no wires are off so I am not really to sure what to check from here. I dont think the battery is dead as it is only 15 months old, always stored inside, never been allowed to run down, nothing has been changed in the last few months and the battery is still taking/holding charge after using the charger?

Hope the picture helps the diagnosis.

Later

IMG_4111.jpg
 
Last edited:
Test it, at high idle. That will make a difference. Even put the sled, on a track stand, and run it up to 4 or 5 grand. At idle, it probably won't be much higher than battery voltage. But, battery charged, should be 12.8

Running off idle, with charged battery, probably 14 to 15 volts, is normal.
 
Anyone have an installation sheet or wiring diagram so I can trace the power source?
 
Last edited:
possible fix

look at the "ice cube style" relay above the clutches zip tied to the frame. In the electric start models the relay is what switches the voltage over to charge the battery, New relay is available through Napa for about $10 or the dealer for $30, replace it then check the voltage again like you did above, should work.
 
How are you making out?

Mine is exactly the same, 07 800r E-start. Battery gets weaker with each start on cold rides. Once sits in heated garage overnight, it fires up with e-start. Battery voltage at that time of test went from 11.6 volts before running, to 13.X volts while idling. Now a few weeks later, it is still at 11.6 volts, but it wont engage starter.

After a bit of testing the batt voltage is now down to 10.0 volts, obviously to low to work properly. I do believe that my battery is dying, currently on the charger.

I can't start mine now as it has no primary clutch on it. Let me know what you find, I am curious now. If I have to replace battery I am going light weight or at least beter, 1000 miles, stored inside all year is sad.
 
Did some more testing.

My battery will definately take and hold charge from the charger so I dont think mine appears to be a battery issue. Mine at idle or 5000+ rpms has absolutely no change in voltage. I unplugged the battery fuse and put in the voltmeter and when I fired it up the sled was actually drawing a bit of power away from the battery.

I wish I new someone with more experience with this electrical system so that I could get some feedback.

I did find a manual and a wiring diagram but both are still vague.

I am confident the problem is in the battery not recieving charge. Now is it a broken wire somewhere I cant see? Is the rectifier gone bad (cant even find it-supposedly 3 yellow wires). Is the stator screwed? Is it possible that the headlights and handwarmers are still running somehow off power from the battery?

Also found out that if my battery is disconnected or the fuse on the battery is pulled the sled will not start. I just assumed that if that battery system was totally dead I could just always pull start it. Not the case.

Would love some insight beyond testing the charging wire right at the battery so that I can trace this problem. What should I be looking for? Where is the rectifier? how can i test output before/after recitifer and stator output? On the can side its such a jumbled mess its hard to really trace or see anything for that matter.

I am guessing that this problem can t be too complicated but knowledge/guidance of this system would sure help.

Later
 
summitsrule said:
How are you making out?

Mine is exactly the same, 07 800r E-start. Battery gets weaker with each start on cold rides. Once sits in heated garage overnight, it fires up with e-start. Battery voltage at that time of test went from 11.6 volts before running, to 13.X volts while idling. Now a few weeks later, it is still at 11.6 volts, but it wont engage starter.

After a bit of testing the batt voltage is now down to 10.0 volts, obviously to low to work properly. I do believe that my battery is dying, currently on the charger.

I can't start mine now as it has no primary clutch on it. Let me know what you find, I am curious now. If I have to replace battery I am going light weight or at least beter, 1000 miles, stored inside all year is sad.
Click to expand...

Yours sounds like more dead battery issue. If you are still getting a charging voltage across your battery but the battery is not taking the charge appears the battery may just be getting weak/old. Mysteriously gaining charge after sitting in the heated garage doesnt make a whole lot of sense? There is the possibility that you have a bad ground or some other source robbing juice?

You could pull the battery and charge it up and see if it holds charge. Maybe stick the charged battery outside overnight and see if you loose voltage.

Just thoughts.
 
Spoke with 5 dealers 4 where either clueless or the "person" that would know was not available. Only 1 of the dealerships gave any sort of advice. They where quit confident that it must be the voltage regulator (200$). Apparently newer systems can have one power source go down with a bad regulator and the other components will be fine. ie. handwarmers/headlights will be fine but no power to the battery. There doesnt appear to be a specific way to test if the regulator is bad.......basically if no power then its your regulator? I can remember on older sleds if the regulator was bad it would fry bulbs and blow fuses. Guess it doesnt work this way anymore? Unfortunately nobody in my riding groups rides revs so can pull off someone elses regulator to check.

Another dealer speculated the relay that runs in line may be faulty and no way to really check it except buy a new one.

There must be someone else that has had this problem out there as e-start is not that uncommon?
 
Problem solved. After numerous hours checking wires and choking on exhaust fumes, it ended up being the relay.

5$ at NAPA and btw the dealer wanted 47.50$ for the same part.
 
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