103-09/10 Tests:
Normal
Abnormal
Cause
Relation between charge
1. More than 15A at 14V
More than 15A at battery
Improper operation of
current and battery voltage more than 15V
regulator
terminal voltage
(at alternator 5000rpm)
2. 15A-0.5A at 14-15V
Charge current OA
Defective alternator or
regulator or improper
connection
Flowing charge current
but low battery voltage
Defective battery
(overdischarge)
Alternator Performance of unit alone
B. Inspection of Flywheel
Turn the flywheel by hand. If 12-time resistance
due
to magnetic force is experienced in one
turn, and
turns relatively smoothly, there is no
trouble in the
flywheel.
If noise is heard during rotation, the bearing is
defective. Replace the bearing.
If the flywheel turns without any resistance, the
magnetic force is too weak.
The magnet should be replaced with new.
-
Disassembly
When the alternator is defective or the flywheel
turns
abnormally, disassemble the alternator as
explained
below.
A. Remove the dust cap (6) using a screw driver.
B. Hold the pulley side jaw of the flywheel complete
(1)
with a vice, loosen the nut
(7).
C. Pull out the spring washer (8) and washer
(9).
D. Pull out the flywheel complete
(1).
If it is hard to
remove, tap the M10 threads with a plastic
hammer.
No load voltage (between
blue and blue) tester
reading
at operation
(about
5000rpm)
Tester
Between
continuity
blue and
blue of
lead wire
Insulation resistance
(
between a lead wire and
coil
plate)
Normal
Abnormal
Cause
More than AC 30V
Less than AC30V AC OV
Demagnetized flywheel,
disconnected coil or
wiring harness
Continuity observed
Continuity not observed
Disconnected coil
More than 3Mtt
Less than 3Mohm
Improper coil insulation
14
1. Flywheel complete
2. Plate complete
3.
Coil plate
4. Stator
complete
5. Bearing
6.
Dust cap
7. Nut
8. Spring washer
9. Washer
10. Coupler
11. Clamp
12.
Screw
13.
Screw 14.
Collar
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