Electrical System 16-27 charging System

• Remove the screws [A] and the holding plate [B] for the stator wiring.

• Unscrew the Allen bolts [C] and remove the stator [D]. Remove the grommet for the crankshaft sensor lead.

Alternator Stator Installation

• Apply silicone sealant [A] around the circumference of the
wiring grommets before setting them in the notch in the
alternator cover.

Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063

• Install the grommet for the stator wiring and crankshaft
sensor lead in this order.

CAUTION

The stator wiring has to be installed along the alter­nator cover without rising away from its surface. If the wires touch the rotor, they will be damaged.

• Tighten the Allen bolts.

Torque - Alternator Stator Allen Bolts: 12 N·m (1.2 kgf·m, 8.5 ft·lb)

• Install the alternator cover (see Alternator Rotor/Starter
Clutch Installation).

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).