Question about Champion International Champion Power Equipment 46515 3500 Watt 196cc OHV 4cycle Gas Powered Rv

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Powerlift gg3500 elecrtic start I have checked stator coils all have restance and not shorted to case (gen would work on 12v dc battery chargeing )function not on AC replaced exciter cap (New) have gen torn down to field armature found a cir board connecting the windings wire broken looked as if melted My problem is (was)this a diode cap cirurit I can't find a wiring diagram for powerlift gg3500 but the chinese made thousands of them could you tell me what I need to replace the defective unit thanks Bob

Posted by robert mangus on

  • robert mangus Nov 21, 2010

    the champion getset was closes thing i found to list under what i have is the powerlift automotive genset GG3500



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2009 Hero Honda Passion Plus charging system

Hi, Anonymous before testing any electrical component in the Charging System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead acid batteries.
1. Battery Test:
The battery needs to be a fully charged and load tested to ensure proper readings, connections need to be clean and tight. If you are not working with a fully charged and functional battery, all other voltage tests will be incorrect. Standing battery Voltage should be 12.5-13.2 DCV.
2. Charging System Voltage Test:
Start motorcycle, measure DC volts across the battery terminals you should have a reading of approximately 13.2-15 DC Volts.
3. Connections and wires:
Inspect the regulator stator plug, and check the battery terminals for connection corrosion. If everything seems to be in order, move on to number 4 below to determine if there's a failed component.
4. Stator Checks/Rotor Check: Each of the following tests isolates the Stator & Rotor. If AC output and resistance test fail and stator test passes then the rotor is at fault (Pull Primary covers and inspect rotor for damage).
5. AC Output Check:
Unplug the regulator plug from the stator start motorcycle and change Voltmeter to AC volts. Probe both stator wires with your meter lead. The motorcycle should be putting out approximately 18-20 ACV per 1,000 rpm. Reading will vary depending on system, check service manual specification
Generic Specs:
22 amp system produces about 19-26 VAC per 1,000 rpm
32 amp system produces about 16-20 VAC per 1,000 rpm
45 amp system produces about 19-26 VAC per 1,000 rpm
Stator Resistance Check:
Switch your multimeter to Ohm x 1 scale. Probe each stator wires with meter leads and check resistance on the meter.
Resistance should be in the range of 0.1-0.5 Ohms. Reading will vary depending on the system, check the service manual for specifications.
Generic Specs:
22 amp system produces about 0.2 to 0.4 ohms
32 amp system produces about 0.1 to 0.2 ohms
45 amp system produces about 0.1 to 0.2 ohms
5. Stator Ground Check:
Switch your multimeter to Ohm x 1 scale.
Probe each stator wire with your positive lead on the multimeter and the negative to ground.
There should be no continuity to ground on either wire.
If there is continuity your stator is shorted to ground and must be replaced.
6. Regulator Test:
Each of the following tests isolates the regulator only, so if any of these tests fail, the regulator is at fault.
Identifying Wires:
Battery Charge Lead- Wire going from regulator to battery positive.
AC output leads- Wires coming from the Stator to the regulator.
Ground- Wire from Regulator to ground or regulator may be grounded via the physical bolting to chassis.
Regulator Ground Test: Ensure the regulator body is grounded or grounding wire is fastened tightly to a good ground (you should verify this by checking continuity from regulator body to chassis ground).
Fwd/Reverse Bias Test/Diode Test:
This check is testing the Diode function to ensure it is regulating the AC current for the stator into DC Current.
Switch multimeter to Diode Scale.
Place your Multimeter positive lead on each AC output wire.
Place your multimeter negative lead on the battery Charge wire.
The meter should read voltage typically around .5 volts.
Next, switch your multimeter leads putting the negative lead on the AC output wires and the Positive lead on the Battery Charge Wire. The reading should be Infinite. With your meter on the same setting, place your multimeter positive lead on the regulator ground wire or to the regulator directly, and then place your meter negative lead on the AC output leads.
The meter should read voltage typically around .5 volts.
Next, switch your multimeter leads putting the negative lead on the regulator ground and the Positive lead on the AC output wires. The reading should be Infinite.
Note: Below is a table to show the readings:
Positive Lead Negative Lead Reading
AC output 1 Battery charge lead Voltage
AC output 2 Battery Charge Lead Voltage
Battery charge lead AC output 1 ?
Battery charge lead AC output 2 ?
Ground AC output 1 Voltage
Ground AC output 2 Voltage
AC output 1 Ground ?
AC output 2 Ground ?
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
Electrical Modification on Hero Honda Passion
How to Test Your Motorcycle Charging System

Btw, I’m available to help over the phone in case u need at

Jul 04, 2017 | 2009 Hero Honda Passion Plus

1 Answer

Battery light stays on my John deer 737 starts good ?

check battery volts with engine off if battery volts on 12v battery ok... check battery running over 12v then battery is charging, stays on 12v battery is not charging ... replace alt. or gen which ever one you have... battery volts drops as running battery needs to be charged or replaced.

May 15, 2017 | Light Garden

1 Answer

Not charging how do i fix this

Determine cause of Not Charging.
Start with a Multimeter on 12v scale.
Check voltage across battery terminals while car is idling.
Voltage should go from 12 v to about 14v when idle is increased.
Check for loose drive belt at Alternator.
Check Alternatir large main + terminal for voltage increasing to 14v which indicates Charging. An Ammeter ca be handy to see if you are getting current of 5 to 40 Amps into battery after using Starter motor.
Check for a small wire connector on the back of Alternator.
This should have Innition Key 12v when key is on.
This supplies the internal electronic regulator which controls current to rotor via the brushes.

If the Alternator is not producing power then Remove it for closer inspection or a replacement unit.

If you wish to tackle repairs to Alternator then place in a vice on workbench.
The Alternator faults break down into the following.
1. Brushes worn down.
Replace brushes & use homemade brush hook/holder to keep the spring loaded brushes compressed while re inserting them.
Mark the case with a scratch or marker before undoing the 3 bolts holding the assembly together.

2. Internal Regulator can often be replaced
3. Internal Diodes may be Bad (Shorted or Open)
4. The Rotor coil damaged
5. The Stator coils shorted or open.

Good Luck

Feb 03, 2016 | LePan 9.7" Capacitive Touchscreen Tablet...

2 Answers

Air bag light stays on also battery and abs

When I had that combination of lights on, it was the alternator. How do you know your alternator is good?

Oct 30, 2015 | 2010 Ford Escape XLS

1 Answer

If I run the generator for several hours it will die do to low charge on battery

Check the battery voltage before you start it at the generator. IE 12V start the generator and measure again. It should be around 13.8V if it does not rise, go to the charge rectifier in the genset and make sure you have AC going onto it. (Assuming you have the gen battery charge option) If you don't have ACV you can suspect the B stator windings, if you do have AC. Check the rectifier DC output 13.8V if present check wiring and fuses, if not present change the rectifier, note where the wires go ! The battery is dying because the ignition system of the gen is pulling it down and it is not charging.

Oct 01, 2013 | Generac Guardian 065795 - battery charger...

1 Answer

My battery goes dead , and its new . bike isnt charging .. what could be the problem also , the model is a kz1000

It may be the stator coils or the regulator.
the stator should have 3 wires coming out, any pair of these should have the same resistance.
no resistance or shorted to earth-stator no good.
with the bike running these three (any pair) put out around 50vAC
so if this is normal ,then its probably the reg\rectifier.
volt meter across the battery will read 12v bike stopped and rise to 13-14v dc bike running if all is well.

voltages can vary between bikes and models, but these should give some idea

Jun 18, 2011 | kawasaki Jog Deluxe Motorcycles

2 Answers

1982 Yamaha XJ 550, the battery will not take a charge. New battery, checked all connections, ran all the tests (stator, brushes, and alternator). Replaced the voltage regulator/recifier. Not sure what is...

It is corrected properly, right? + to the wiring harness and - to ground ... right? Are you certain about the rectifier? Is the battery charged at this time?

You know a alternator cannot make power unless you first put power into it ... right? Alternators (unlike most generators) are not self exciting. If your battery is weak or "dead", the alternator cannot make electricity to charge the battery. I don't know what the rating of your alternator is. Your battery should be fully charged before you do any more tests. If you have a 1 amp charger, allow at least 10 hours for a full charge. Don't cook your battery with a big, powerful, fast charging automotive battery charger.

Good luck with your repair ... I hope you find this response helpful.

Thanks for your question @

May 02, 2011 | Yamaha XJ 650 Motorcycles

1 Answer

2000 flhtcui after driving couple hours my charging system drops

Are you sure your gauge is not lying to you? Ride the bike until you see that your charging voltage has dropped. Then check the voltage directly across the battery with a meter. If it is indeed below the 14 volt mark, you are either drawing too much current or your alternator is not putting out enough.

To check the alternator, unplug the regulator where it plugs into the engine case. Down inside the plug in the case, you'll see either two sockets or two pins. Using a digital volt ohm meter (DVOM) put one lead to pin or socket and the other lead to the other pin or socket. Put the meter in the 50 volt AC range. The voltage coming out of the alternator is AC voltage, not DC. It is converted to DC by the regulator. Start the engine an bring the engine up to a high idle. You should read 32-40 volts AC. If so, you stator is good and working as it should.

Now, you're left with either something drawing too much current or a bad regulator. The book tells you how to check the regulator but you must use a specific type of meter or you'll get erronous readings. If you have added a lot of extra lights to the bike, this could be overworking the alternator. Check the ground on the regulator to the frame. It must be grounded well.

Apr 06, 2010 | 2000 Harley Davidson FLHTCUI Electra Glide...

2 Answers

2003 Yumbo Dakar 200 Motorcycle

Hi and welcome to FixYa,

Interesting, could not find any service information either. And have not had the chance to work on one.

In any case, your post "Any advice?", since battery is new, then there would only be 2 possibilities (aside from the fuse & wiring):
voltage regulator; and/or
stator windings.
The voltage regulator as the name implies regulate the voltage coming from the stator/alternator. It also converts the AC into DC to charge the battery and supply the electrical requirement of the bike when the engine is running. Most voltage regulators would look like the image below.
The stator windings are the coil inside where the magneto spins inside either. It is the alternator of the bike and produces the AC voltage that supplies the regulator. A stator would look like the image below. The red coil of copper wires.
Good luck and Thank you for using FixYa.

Jan 04, 2009 | 2004 Yumbo Dakar 200

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