TOHATSU 200 Series Service Manual page 124

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CHARGING SYSTEM
CHARGING SYSTEM TROUBLESHOOTING
CHARGING SYSTEM
BATTERY IS DAMAGED OR WEAK
(*) Refer to page of base shop manual (BF175AK1·200AK1·225AK1: 62ZY300).
1. Battery test
Remove the battery.
Check the battery condition using the commercially available battery tester.
Is the battery in good condition?
YES
NO
2. Fuse inspection
Check for blown No.1 (150 A) fuse and No.10 fuse (10 A).
Is it normal?
YES
NO
3. Load Inspection
Check whether an excessive load is connected.
Is the load normal?
YES
NO
4. Alternator terminal inspection
Check the alternator B terminal and 4P connector
Is it normal?
YES
NO
5. Alternator wire inspection
Check for open in the alternator wire.
Are they normal?
YES
NO
6. Alternator belt inspection
Check the alternator belt for looseness and damage (page 3-11*).
Is it normal?
YES
NO
7. Alternator inspection
Inspect the following alternator parts:
– Blush (page 7-15*)
– Rectifier (page 7-15*)
– Rotor (page 7-16*)
– Stator (page 7-16*)
Are they normal?
YES
NO
7-2
– GO TO STEP 2.
– Faulty battery.
– GO TO STEP 3.
– Battery connected incorrectly or reverse polarity.
• Check for short in the main wire harness
• Incorrect load by referring to the fuse load chart (page 4-4)
• Replace the blown fuse
– GO TO STEP 4.
– Remove the load and recheck.
– GO TO STEP 5.
– Connect the terminal and/or connector securely.
– GO TO STEP 6.
– Repair the open circuit in the alternator wire.
– GO TO STEP 7.
– Adjust or replace the alternator belt (page 3-11*).
– Replace the IC regulator with a new one and recheck.
– Replace the faulty part(s).
terminal for looseness and damage.