help! chargeing problem since mad bypass!!

HOW IT WORKS. Ignition power from the switch is fed to the VR IGN terminal and to one of the two field terminals on the alternator. The power to the VR does two things, power the VR, and act as "sensing" voltage

The VR controls "the amount of ground" so to speak through the green wire.

1..........Determine if the alternator can charge. Unhook the green field wire at the alternator, hook a clip lead to the now exposed alternator terminal and hook to ground. Turn the key to "run," engine OFF. Take a voltmeter and check the blue field connection at the alternator, still hooked up, with your clip lead grounded on the opposite terminal. See if you have "close to" battery voltage at the blue wire. If you like, you can hook / unhook/ hook up the clip lead and in subdued lighting, should see a small spark, indicating the field is conducting power

If you don't see conduction, (no spark) and or have no voltage at the blue wire (key on) then you have found part of the problem, or all of it. Find out why you are not getting V on the blue wire with the key "in run."

Meanwhile, you can "substitute" for the blue wire by running a clip lead to a battery connection (starter relay large stud) to the "blue" field terminal.

2.....Now start the engine and slowly bring up RPM while monitoring battery voltage. V should increase, depending on how discharged the battery is, to over 13 or 14. Don't let the V get above 16.

If this does not happen, move your meter to the large black output stud. Again, bring up RPM. On a good unit, this voltage should be close to what you saw at the battery PLUS as much as 1, 1 1/2 volts or so.

IF YOU get quite high voltage at the output stud, maybe 18 or more, but low (12 or less) at the battery, YOU HAVE an open in this output wire


Let's say it DOES charge OK with the above tests. Maybe remaining field circuit problem, or bad VR?

3.....So, hook wiring up "per normal." Unplug the VR connector and inspect. Should be tight, and not corroded. "Rig" a way to jumper across the two wire terminals in the VR connector, such as small machine screws.

Now, unhook the BLUE field at the alternator and ground that exposed alternator terminal. With the key in run, you should again see a spark as you unhook / hook up the clip lead. With the clip grounded, you should now see "about" battery voltage on the GREEN terminal at the alternator.

Now repeat your run test. If it brings up voltage as before,

First scrape clean and re--mount the VR. It MUST be grounded!!! Must be clean and tight. Use star lock washers.

With everything normal, if the above tests give positive results, replace the VR.