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INSTALLING
1. Place the alternator/regulator into position on the
engine; then secure with the existing hardware. Do
not tighten at this time.
2. Place the alternator drive belt into position; then
using a suitable pry, tension the drive belt so that a
10 kg (22 lb) force applied at the midway point will
result in a deflection of 10-15 mm (0.4-0.6 in.).
DE103B
3. Holding tension on the belt, tighten the adjuster cap
screw securely; then remove the pry and tighten the
pivot bolt securely.
4. Connect the battery (B+) wire and connect the regu-
lator control plug-in; then connect the negative bat-
tery cable to the battery.
5. Install the left-side engine cover and seat making
sure the seat latches securely.
Headlights
The connectors are the four 2-prong ones secured to the
front bumper supports (two on each side) with cable ties.
BULB VERIFICATION
(Low and High Beam)
NOTE: Perform this test on each headlight bulb.
Also, a 12-volt external power supply w/jumpers will
be needed.
1. Disconnect the wiring harness from the bulb to be
tested.
2. Connect the power supply (positive) to one bulb con-
tact; then connect the power supply (negative) to the
remaining bulb contact.
3. The bulb should illuminate.
4. If the bulb fails to illuminate, it must be replaced.
VOLTAGE
NOTE: Perform this test in turn on the main harness
side of all four connectors. Also, the ignition switch
must be in the LIGHTS position.
NOTE: The LO beam is the outside bulb, and the HI
beam is the inside bulb.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to one wire; then connect
the black tester lead to the other wire.
3. With the dimmer switch in the LO position, test the
two outside connectors (LO beam). The meter must
show battery voltage.
4. With the dimmer switch in the HI position, test the
two inside connectors (HI beam). The meter must
show battery voltage.
NOTE: If battery voltage is not shown in any test,
inspect the fuses, battery, main wiring harness, con-
nectors, or the left handlebar switch.
Taillight - Brakelight
The connector is the 3-prong one located under the rear
fender assembly.
VOLTAGE (Taillight)
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
the LIGHTS position.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the white wire; then
connect the black tester lead to the black wire.
3. With the ignition key in the LIGHTS position, the
meter must show battery voltage.
NOTE: If the meter shows no voltage, inspect fuses,
wiring harness, connectors, and switches.
VOLTAGE (Brakelight)
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
the ON position and the brake (either foot pedal or
hand lever) must be applied.
NOTE: Make sure the brake lever (hand) and brake
pedal (auxiliary) are properly adjusted for this proce-
dure.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the red/blue wire; then
connect the black tester lead to the black wire.
3. With either brake applied, the meter must show bat-
tery voltage.
NOTE: If the meter shows no voltage, inspect bulb,
fuses, wiring harness, connectors, and switches.
