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Alternator
Consists of 2 main parts: Rotor and Stator
The Rotor is attached to the crankshaft and has a series of permanent magnets. The Stator is attached to the crank case and has a series of wound wire coils.
The rotating magnetic fields around the stationary coils induces an AC Voltage in the coils.
Rotor

Stator

The 3 phase AC Voltage from the stator is sent to the Voltage Regulator to be rectified to DC Voltage and to be regulated to a useable limit, generally just over 14.5 Volts.
The output of the Voltage regulator is connected to the battery. The positive output goes through the Maxi fuse and to the starter before connecting to the Battery.
Battery testing
First check and clean battery terminals and ground cables.
Voltmeter test:
Connect voltmeter positive to positive terminal on battery and voltmeter negative to battery negative terminal.
12.7 v = 100% charge
12.6 v = 75%
12.3 v = 50%
12.0 v = 25%
11.8 v = 0%
If you are unsure of the battery’s condition charge it fully and take it to an auto parts store and have it load tested. If the Battery passes all tests check the charging system.



Charging System Testing
With the bike in neutral and voltmeter attached to the battery start the engine and rev to 3,000 rpm. If the voltage measures 13 v – 14.7 V the charging system is operating properly. Voltage above 14.7 V indicates the voltage regulator may be bad.
Stator testing
If less than 13v disconnect the Stator from the Voltage Regulator.
The end of the connector from the stator has 3 sockets. Set your meter to ohms and connect one lead to the battery negative. With the other lead make contact with the conductor inside each socket. You are checking for a grounded wire, each socket should show an open circuit to ground, no continuity.
Now take the lead you had on the battery negative and with both leads check resistance between each of the three sockets, 1-2, 2-3 and 1-3. The resistance should be 0.1 – 0.3 ohm.
Next check the Stator’s AC output. With the Stator unplugged from the VR and the bike in neutral, start the bike. Run the bike at 2,000 rpm and check the Stator output between sockets 1-2, 2-3 and 1-3. The voltage should read approximately 32-46 Volts AC.

Approximate Spec’s:
22 amp system 19 – 26 vac per 1,000 rpm
32 amp system 16 – 20 vac per 1,000 rpm
45 amp system 19 – 26 vac per 1,000 rpm

One other indication that the stator may be bad is if your primary oil smells like a burnt circuit board.