5.2. Hight Voltage Tester

1.              Intended use

HV tester is designed for a simple check of high-voltage ignition systems operation (HV modules anf HV cables) directly on the engine without dismantling. The check is carried out in the engine start mode. The tester indicates with flashing light that the ignition module is able to generate sufficient electrical pulse which via the spark plug ignites the mixture in the engine cylinder.

 

2.              The kit contains

  • Case……………………………………………………………….. 1pc
  • HV load of 2.5 kV……………………………………………. 1pc
  • HV load of 5 kV………………………………………………. 1pc
  • HV load of 10 kV…………………………………………….. 1pc
  • HV load of 15 kV…………………………………………….. 1pc
  • HV indicator……………………………………………………. 1pc
  • ground cable………………………………………………….. 1pc
  • T- adapter……………………………………………………….. 1pc
  • cable nut M4/Al, spare……………………………………. 7pc

 

 

3.              Test procedure

3.1             Single-outlet (single-spark) ignition module

– i.e. each engine cylinder has its own ignition module

 

 

3.1.1        Step 1

 

Connect the HV load in place of the spark plug, see Fig. 1

 

Fig. 1

Select the required test voltage by selecting the size and number of HV loads connected in series; the resulting test voltage is the sum of voltages of the individual HV loads. Selection of the configuration and therefore the resulting value of high voltage is a key criterion for verifying the proper operation of the ignition system – see evaluation below! Insert the HV indicator into the hole of the HV load with the arrow towards you for good visibility of the fleshing light. Attach the HV indicator clip to a metal part of the engine to ensure a reliable electrical connection to the motor frame even during vibrations when carrying out the test.

 

Warning: Failure to attach the ground clip, or if the clip is disconnected during the test, may result in damage to the unloaded ignition module!

 

3.1.2        step 2
To prevent the engine start during the test, disconnect also the HV cables of the other spark plugs and connect them via ground cables to a reliable engine ground – see Fig. 2

 

 

Fig. 2

Warning: Test with the HV cable disconnected from the ignition module without its grounding can cause damage to the unloaded ignition module!

 

 

3.1.3        step 3

Start the engine for short periods of 2 to 3 seconds and check that the HV indicator is flashing.

 

 

3.1.4        Test evaluation
The tester uses flashing light to indicate current pulses which a properly operating ignition module is able to deliver to the HV load at voltage given by the load size. The minimum value of the load determines the necessary condition for the proper evaluation of the test. If, with correctly selected value of the load, there are no regular light flashes on the indicator, the ignition module, or the high-voltage cable, is faulty.
From the performed measurements, you can detect the minimum load at which the indicator should be flashing. The minimum value of the load for the H-D bikes® is 25 kV

 

Notes:

  • Voltage of the ignition module may be dependent on the battery status. Only perform the measurements with the battery charged
  • You can find a video of the HV tester use at

 

 

 

3.2             Two-outlet (dual-spark) ignition module
– i.e. one ignition coil for two engine cylinders
Two-outlet (dual-spark) ignition modules can be tested in a way similar to the procedure in 3.1. You can see the wiring diagram in Fig. 3. The other ignition modules must be grounded.

 

Fig. 3

Test evaluation is the same as for the single-outlet (single-spark) ignition modules.

 

4.              Further use

The HV tester kit contains a T-adapter which can be used to check the flash-over voltage on the spark plug at idle speed. You can see the wiring diagram in Fig. 4.

Fig. 4

4.1             Test procedure

  1. Assemble the HV tester for a total load value of 25 kV.
  2. Connect the HV tester according to Fig. 4
  3. Start the engine. The HV indicator should not be flashing and the engine must run evenly.
  4. Decrease the value of HV load by 2.5 kV and check whether the engine is running evenly.
  5. If the engine is running evenly, repeat step d) until the engine stops running evenly or stops, or until it cannot be started again. In this case, the value of flash-over voltage on the spark plug is equal to or greater than the total HV load.

 

Perform each step with the motor stopped.

 

 

5.              Safety precautions

  • Always connect the HV tester to the ignition module with the engine stopped and the ignition off.
  • Make sure the electrical connection and grounding is reliable with regard to possible vibration during engine start.
  • Failure to attach the ground clip, or if the clip is disconnected during the test, may result in damage to the unloaded ignition module.
  • Do not touch any part of the HV tester or the ignition module during the test.
  • The ignition module generates high voltage which can cause injury when in contact with the human body.

 

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