Hi,

I'm working on my bosses 1991 Trail Boss 4x4 and I found out the charging system is not working. I could really use a wiring diagram, and I couple of specs. The headlights don't work either, there maybe a common link. If anyone knows any common problems any tips would be great.

Thanks,
Jake

 

Usually reg/rectifier located under headlight,especially if not charging while above 3000 rpm(13.5-14.5 volts) Most of burnt out headlight problems are from pull staring when battery bad,surges and pops lights and indicator bulbs. If charging ok,but battery BAD,can cause same problem, battery wont accept voltage and power will find some path to flow usually through lights which have least resistance.

 

Well, I haven't been able to locate a book locally without having to order it. I'm guessing it's the voltage rectifier too, but I want to make sure before buying a $100 part. Does anyone know what wires to check for AC voltage off the stator and roughly how much voltage should there be. I want to make sure stator is putting out first.


Thanks,
Jake

 

Cant remember off hand (thats why I have manuals so I wont have to) but think ac voltage should be about 25-40 volts. In 20 years have had only ONE stator that was charging over 75 ac volts that fried reg/rectifier. A quick test is to see if yellow wire is NOT shorting to ground.Check resistance between yellows and yellow with red stripe(I think) Should be about equal. Still betting on reg/rectifier if battery is good!