DRIVE BELTS
Note. If the belt is too loose, it will cause noise or sudden wear. If the belt is too tight, the engine coolant pump bearing or the generator can get damaged.
Possible Causes
- Fuse blown.
- Light burned out.
- Wiring connections loose.
- Electronic voltage regulator faulty.
Possible Corrections
- Check fuses.
- Replace light.
- Tighten loose connections.
- Replace voltage regulator.
- Generator drive belt loose or worn.
- Battery cables loose, corroded or worn.
- Fuse blown.
- Fusible link blown.
- Electronic voltage regulator or generator faulty.
- Wiring fault.
- Adjust tension or replace generator drive belt.
- Repair or replace cables.
- Check fuses.
- Replace fusible link.
- Test generator.
- Repair wiring.
- Generator drive belt loose or worn.
- Wiring connections loose or open circuit.
- Fusible link blown.
- Warning indicator and pre-excitation resistor faulty.
- Poor ground.
- Electronic voltage regulator or generator faulty.
- Battery.
- Adjust tension or replace generator drive belt.
- Tighten loose connections or repair wiring.
- Replace fusible link.
- Replace light, resistor or related components as necessary.
- Repair ground.
- Test generator.
- Replace battery.
- Drive belt loose or worn.
- Wiring connection loose or open circuit.
- Fusible link blown.
- Poor ground.
- Electronic voltage regulator or generator faulty.
- Faulty battery.
- Electronic voltage regulator faulty.
- Voltage sensing wire faulty.
- Adjust tension or replace drive belt. See «DRIVE BELTS»(ref-167604-S39524377352004101800000) under ADJUSTMENTS.
- Tighten loose connection or repair wiring.
- Replace fusible link.
- Repair grounds.
- Test generator, if faulty, repair or replace as necessary.
- Replace battery.
- Replace voltage regulator.
- Repair wiring.
CHECKING STATOR POWER SOURCE CIRCUIT
Note. For circuit identification, see WIRING DIAGRAMS .
BRUSHES (2003 ONLY)
Note. Manufacturer does not provide information for brushes on 2004 models at this time.
- Replace brushes if worn to limit line. (Scheme 34) Replace all brush springs if any springs are damaged or corroded.
- To remove brushes from holder, unsolder pigtail from terminal. (Scheme 35) To replace, install brush and spring so that space between limit line and brush holder end is 0.079-0.118" (2.0-3.0 mm), and solder pigtail to brush holder.
Scheme 34
Scheme 35
ROTOR
- Measure resistance between rotor slip rings. (Scheme 36) Resistance should be 3.1 ohms. If resistance is as specified, go to next step. If resistance is extremely low or high, replace rotor assembly.
- Check continuity between each slip ring and rotor core. (Scheme 37) There should be no continuity between either slip ring and rotor core. If continuity exists, rotor is shorted internally. Replace rotor assembly.
Scheme 36
Scheme 37
STATOR
- Check continuity between stator coil leads. (Scheme 38) If continuity exists, go to next step. If continuity does not exist, replace stator assembly.
- Check continuity between each stator coil lead and stator core. (Scheme 39) There should be no continuity between any stator coil lead and stator core. If continuity exists, replace stator assembly.
Scheme 38
Scheme 39
2003
See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
2004
See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.