ELECTRICAL - 2B-5
90-824052R3 JUNE 2002
Battery Charging System
Troubleshooting
General Troubleshooting
A fault in the battery charging system will usually
cause the battery to become UNDERCHARGED. A
defective VOLTAGE REGULATOR may also allow
the system to OVERCHARGE the battery.
If a problem exists in the charging system, visually
check the following:
1. Check for correct battery polarity [RED cable to
(+) POSITIVE battery terminal].
NOTE: 40 AMP CHARGING SYSTEM voltage
regulator/rectifier is protected internally against
incorrectly installed battery cables.
2. Check for loose or corroded battery terminals.
3. Check condition of the battery.
4. Visually inspect all wiring between stator and
battery for cuts, chafing and disconnected, loose
or corroded connections.
5. Excessive electrical load (from too many
accessories) will cause battery to run down, even
if the system is operating correctly.
If the system is still OVERCHARGING the battery,
the VOLTAGE REGULATOR is most likely defective
and should be replaced.
If the battery is UNDERCHARGED, proceed with
REGULATOR, STATOR, and RECTIFIER tests,
following.
40 Ampere Alternator System
40 AMP STATOR TEST (ALTERNATOR COILS
ONLY)
NOTE: Stator can be tested without removing from
engine.
1. Disconnect 2 short YELLOW and 2 long YEL-
LOW stator leads from bullet connectors at rear
of engine above ignition coil plate.
2. Use an ohmmeter and perform the following test:
Test Leads To-
Resistance
(Ohms)
Scale
Reading
Connect test leads
between 2 short
YELLOW and 2
long YELLOW
stator leads
.25-.45* R x 1
RED test lead to 1
short YELLOW (or
long YELLOW)
stator lead, and
BLACK test lead to
engine ground if
stator is mounted or
to steel frame of
stator (if off engine)
No
Continuity
R x 1000
* Resistance of these windings generally is less than
one ohm. A reading, that resembles a short, is
acceptable. Copper wire is an excellent conductor
but will have noticeable differences from cold to hot.
Reasonable variation from specified reading is
acceptable.
3. If meter readings are other than specified, re-
place stator assembly Refer to stator assembly
replacement in Section 2A.
TROUBLESHOOTING 40 AMP
ALTERNATOR SYSTEM
WARNING
Before connecting or disconnecting any
electrical connection, battery cables MUST BE
REMOVED from battery to prevent possible
personal injury or damage to equipment.
IMPORTANT: The charging system may be
connected to one or more batteries during these
tests. However, these batteries MUST BE fully
charged. These batteries MUST NOT BE
connected to any other charging source.
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