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NOTE: If voltage rises above 15.5 DC volts, the reg-
ulator is faulty or a battery connection is loose or cor-
roded. Clean and tighten battery connections or
replace the alternator. If voltage does not rise, check
all battery connections, the battery (B+) wire on the
alternator, and the voltage regulator control plug-in. If
all are normal, replace the alternator.
REMOVING
1. Remove the negative battery cable from the battery;
then remove the seat and left-side engine cover.
2. Disconnect the battery (B+) wire from the alternator;
then disconnect the voltage regulator control plug-in.
DE519B
3. Loosen the alternator adjuster cap screw (A) and the
pivot bolt (B); then remove the alternator drive belt.
DE519C
DE103C
4. Remove the adjuster cap screw and pivot bolt and
remove the alternator.
NOTE: The alternator/regulator is not a serviceable
part; therefore, it must be replaced as an assembly.
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.
Manual
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