325 

 

Over-high or over-low recharging 
voltage from generator 

Loosing or over worn-out of generator belt 

Replace generator 
belt 

Loosing or bad contact of fuse of generator 

Change fuse 

Malfunction of generator regulator 

Replace generator 
regulator 

Malfunction of generator rectifier 

Sulfurization or short-circuit of internal battery 
plate 

Replace generator rectifier or generator 
assembly 

Replace battery

Normal 

Sulfurization 
or 
short-circuit

Normal 

Normal 

Normal 

Abnormal 

Abnormal 

Abnormal 

Abnormal 

 
 

 

 

326 

 

No. 233 Generator can’t work   

Malfunction 

Cause 

Solution   

Malfunction of generator 
belt  

Check generator belt for tension and wearing condition and if there is 10 mm of 
flexibility in the middle of belt under 50 N pressure; if the belt is over-loosing or over 
worn-out, the generator belt should be adjusted or replaced;   

Malfunction of fuse   

Check fuse of generator (60A) for break; if it’s broken, the generator fuse should be 
replaced;   

Malfunction of generator 
regulator  

Check if generator regulator is able to adjust generated voltage; if it’s abnormal, 
regulator or generator assembly should be replaced;   

1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of 
rectifying diode, and the other probe to every end of rectifiers; changeover the 
polarity of probes and repeat above procedure; the Ohm meter will show 
conducting for one and cutoff for the other; if the conductivity is different from above 
description, the rectifier or generator assembly should be replaced;   

Malfunction of generator 
rectifier  

2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of 
rectifying diode, and the other probe to every end of rectifiers; changeover the 
polarity of probes and repeat above procedure; the Ohm meter will show 
conducting for one and cutoff for the other; if the conductivity is different from above 
description, the rectifier or generator assembly should be replaced.   

Malfunction of stator coil of 
generator  

1. Place multi-meter to Rx1 grade and connect two probes to any two leads of 
armature windings; they should be connected; if the resistance is infinite, it 
indicates that the break results in failure of generator, thus the coil or generator 
assembly should be replaced; 2. Check windings with bond strap: Place 
multi-meter to Rx1 grade and connect one probe to any lead of armature winding 
and the other probe to core of stator; if the resistance is infinite, the insulation of 
armature windings is good, otherwise the coil or generator assembly should be 
replaced;  

Malfunction of rotator coil 
of generator   

1. Check resistance of rotator windings: Place multi-meter to Rx1 grade and 
connect two slip rings; the standard resistance should be 2.7 – 3.1 Ohm; if the 
resistance is different from standard, the rotator or generator assembly should be 
replaced; 2. Check flexibility of rotator: The radial swinging standard should be less 
than 0.5 mm; if it's abnormal, the generator assembly should be replaced;   

Malfunction of internal 
brush for engine   

The length standard of exposed brush measured by vernier caliper should be 10.5 
mm and the minimum length should be 1.5 mm; if the length is smaller than the 
minimum length, the brush or generator assembly should be replaced;   

Generator can’t 
work 

Malfunction of harness   

Check the harness of generator for short-circuit or poor contact, if it's abnormal, the 
generator harness should be checked and repaired;   

 

 
 

 

 

327 

 

Generator can’t 
work 

Loosing or over worn-out of generator belt 

Adjust or replace generator belt 

Broken fuse of generator 

Replace fuse 

Generator regulator in poor operation 

Replace starter 
assembly 

Open circuit or short-circuit of stator coil of generator 

Replace generator 
assembly 

Damage of internal brush or rotator for generator 

Replace generator 
assembly 

Generator rectifier in poor operation 

Replace rectifier or generator 

Check and repair 
generator loop 

Loosing or break of wire for connectors of generator 

 
 

 

 

328 

 

No. 234 Charging indicator of generator is always on or not on   

Malfunction Cause 

Solution 

Malfunction of 
generator belt   

Check generator belt for tension and wearing condition and if there is 10 mm of flexibility 
at middle of belt under 50 N pressure; if the belt is over-loosing or over worn-out, the 
generator belt should be adjusted or replaced;   

Malfunction of 
generator regulator 

Check if generator regulator is able to adjust generated voltage; if it’s abnormal, 
regulator or generator assembly should be replaced;   

1. Check forward rectifying: Connect one probe of Ohm meter to positive pole of 
rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of 
probes and repeat above procedure; the Ohm meter will show conducting for one and 
cutoff for the other; if the conductivity is different from above description, the rectifier or 
generator assembly should be replaced.   

Malfunction of 
generator rectifier   

2. Check backward rectifying: Connect one probe of Ohm meter to negative pole of 
rectifying diode, and the other probe to every end of rectifiers; changeover the polarity of 
probes and repeat above procedure; the Ohm meter will show conducting for one and 
cutoff for the other; if the conductivity is different from above description, the rectifier or 
generator assembly should be replaced;   

Malfunction of 
generator fuse   

Check positive pole fuse of generator for conducting; if it’s broken, the generator fuse 
should be replaced;   

Malfunction of 
combined instrument   

Check indicating diode of combined instrument for mixed connection or breakdown; if 
it’s abnormal, the combined instrument should be replaced;   

Malfunction of harness  Check charging loop for good contact; if it’s abnormal, check or repair the loop;   

Charging 
indicator of 
generator is 
always on or not 
on 
 

Malfunction of battery    Replace battery assembly;   

 

Replace generator 
belt

Loosing or over worn-out of generator belt 

Check or repair charging indicator 
loop of generator

Short-circuit or open circuit of charging indicator loop of 
generator

Replace generator 
regulator

Generator regulator in poor operation 

Change fuse 

Broken fuse of generator 

Replace rectifier or generator 
assembly

Generator rectifier in poor operation 

Replace 
combined

Short-circuit or open circuit of internal charging indicator of 
combined instrument

Charging indicator of generator is always on
or not on 

Abnormal

Normal 

Normal 

Normal 

Normal 

Normal 

Abnormal

Abnormal

Abnormal

Broken

Worn-out

Normal 

Normal