Step 1

Remove and clean all charging system electrical connections from the alternator, the batteries and wire runs (this includes the ground side). Next, check the voltage regulator’s harness for resistance with a multimeter. Wires and terminals can and will become corroded over time, and may need to be cleaned or replaced. Then check all fusing in the regulator harness and alternator output cables.

• Remove & clean all connections & terminals
• Test the harness for high resistance
• Check the fuses

Step 2

Charge all batteries to their proper fully charged state and determine if they are serviceable.
If your batteries are flooded-type, use your hydrometer to determine their condition.

• Fully charge the batteries.
• Measure the voltage with a multimeter, and if lead-acid, check with a hydrometer.

Step 3

Check and tighten the alternator belt. If the belt shows signs of wear or damage, replace the belt or belts. Always replace existing belts with the finest quality replacements available. In applications where dual belts are used, always try to replace both belts at the same time with matched belts.

• Check belts for damage & wear. If in doubt, chuck em out.
• Replace with quality belts, replace both if a dual pulley.

 
Initial System Troubleshooting