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Problem: Magneto overcharges
Condition Remedy
1. Internal battery short circuited
2. Regulator/rectifier resistor damaged - defective
3. Regulator/rectifier poorly grounded
1. Replace battery
2. Replace resistor
3. Clean - tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting
2. Magneto internally shorted
3. Regulator/rectifier defective
1. Replace lead wire
2. Replace magneto
3. Replace regulator/rectifier
Problem: Starter button not effective
Condition Remedy
1. Battery charge low
2. Switch contacts defective
3. Starter motor brushes not seating
4. Starter relay defective
5. Emergency stop - ignition switch off
6. Wiring connections loose - disconnected
1. Charge - replace battery
2. Replace switch
3. Replace starter motor
4. Replace relay
5. Turn on switches
6. Connect - tighten - repair connections
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low - too high
2. Battery electrolyte insufficient
3. Specific gravity too low
4. Battery run-down - damaged
5. Electrolyte contaminated
1. Replace battery
2. Keep electrolyte to prescribed level
3. Charge battery - add distilled water
4. Replace battery
5. Replace battery
Problem: Battery discharges too rapidly
Condition Remedy
1. Electrolyte contaminated
2. Specific gravity too low
3. Charging system not charging
4. Cell plates overcharged - damaged
5. Battery short-circuited
6. Specific gravity too low
1. Replace battery
2. Charge battery - add distilled water
3. Check magneto - regulator/rectifier - circuit connections
4. Replace battery - correct charging system
5. Replace battery
6. Charge battery
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections - replace battery - repair damage
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