ELECTRICAL
5.10
G Connect the meter leads to the
Yellow/Red and Black wires leading
from the alternator.
G Start the engine using the kick
staRter and let it idle. Reading
should be a minimum of 3A at idle.
CAUTION: Thistest simulatesa“fullload” on the
alternator. Do not perform this test longer than
required to obtain a reading or the alternator
stator windings may overheat. 3-5 seconds is
acceptable. Do not rev the engine during the test.
Alternator Current Output:
Minimum of 3 AC Amps
IGNITION
The ignition system has been upgraded for durability
by encapsulating the stator with an epoxy coating.
RPM speed limiting is now contained within the CDI
Module. Exhaust restrictors have been removed.
SPARK PLUG
Spark Plug: NGK BPR7HS (PN 0450005)
Plug Gap
.024--.028”
(.6--.7mm)
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
G Battery discharged
G Loose or faulty battery cables or
corroded connections (see Voltage
Drop Tests)
G Related wiring loose, disconnected,
or corroded
G Poor ground connections at battery
cable, starter motor or starter
solenoid (see Voltage Drop Tests)
G Faulty starter button
G Faulty ignition switch (Do other
systems function?)
G Faulty starter solenoid or starter
motor.
G Engine problem - seized or binding
(Can engine be rotated with kick
starter?)
Starter Motor Turns Over Slowly
G Battery discharged
G Excessive circuit resistance - poor
connections (see Voltage Drop Test
below)
G Engine problem - seized or binding
(Can engine be rotated easily with
kick starter?)
G Faulty or worn brushes in starter
motor
Starter Motor Turns - Engine Does Not Rotate
G Faulty starter drive
G Faulty starter drive gear or starter
motor gear
G Faulty flywheel gear or loose
components
VOLTAGE DROP TEST
The Voltage Drop Test is used to test for bad
connections. When performing the test, you are
testing the amount of voltage drop through the
connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on
the meter when testing connections should not
exceed .1 VDC per connection or component
.
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be
tested. Refer to the chart to perform voltage drop
tests on the starter system.
Voltage should not exceed
.1 DC volts per connection
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