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Alternator Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Table of Contents
Charging System

Alternator Inspection

There are three types of alternator failures: short, open
(wire burned out), or loss in rotor magnetism. A short or
open in one of the coil wires will result in either a low output
or no output at all. A loss in rotor magnetism, which may
be caused by dropping or hitting the alternator, by leaving
it near an electromagnetic field, or just by aging, will result
in low output.
To check the alternator output voltage, do the follow-
ing procedures. Refer to the appropriate chapters and
Charging System Wiring Diagram.
Turn off the ignition switch.
Remove the left side cover.
Disconnect the alternator lead connector [A].
Connect the hand tester as shown in the table 1.
Special Tool - Hand Tester: 57001-1394
Start the engine.
Run it at the rpm given in the table 1.
Note the voltage readings (total 3 measurements).
Table 1 Alternator Output Voltage
Tester (+) to
250 V AC One yellow lead
If the output voltage shows the value in the table 1, the
alternator operates properly and the regulator/rectifier is
damaged. A much lower reading than that given in the
table indicates that the alternator is defective.
Check the stator coil resistance as follows:
Stop the engine.
Connect the hand tester as shown in the table 2.
Note the readings (total 3 measurements).
Table 2 Stator Coil Resistance
Tester (+) to
One yellow lead
× 1 Ω
(Connector 3)
If there is more resistance than shown in the table, or
no meter reading (infinity) for any two leads, the stator
has an open lead and must be replaced. Much less than
this resistance means the stator is shorted, and must be
Using the highest resistance range of the hand tester,
measure the resistance between each of the yellow leads
and chassis ground. Any hand tester reading less than
infinity (∞) indicates a short, necessitating stator replace-
If the stator coil has normal resistance, but the voltage
check shows the alternator to be defective; then the rotor
magnets have probably weakened, and the rotor must be
Tester (−) to
Another yellow
Tester (−) to
Another yellow lead
(Connector 3)
Reading @4
000 rpm
About 60 V
0.3 ∼ 0.6 Ω


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Vulcan 500 ltd

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens