Kawasaki 540 charging help

rrobert · Apr 25, 2012

Mid 1980s John Deere 185 Hydro with a 540 Kawasaki engine. Electric PTO.

I messed up and connected the battery backwards. It started and ran fine. We used it for about 2 hours like that before I realized the error. Connected the battery correctly. I replaced the 20amp fuse(assuming alt fuse). The battery light is still lit on the dash.

The battery had 12.4 volts before starting. After starting and running, battery voltage kept creeping up to 12.8 after 2 minutes and the battery light was still on. Fuse is ok. Is it charging? Did I ruin the alternator, voltage regulator, ignition, relay or something else?

Any test suggestions? I will take a look at it in the morning if I have time.

Thanks, robert

El Toro · Apr 26, 2012

Measure the battery voltage across the battery terminals with the engine at 1/2 throttle or better using a volt meter. Should see around 14 volts. Also if that engine has a rectifier/regulator measure the AC voltage should see about 30 volts AC. If there's no ac volts you may have fried the stator. Hal

RonnieGraves · Apr 26, 2012

did that one time , but the starter would spin and not engage it was turning the wrong way ,
pull the flywheel and look at the stator it is more than likely burned

rrobert · Apr 27, 2012

I have changed over 100 batteries since I was 12. This is the first time except for the 63 Falcoln that I did this. It was 6 volts (+ ground). How was I supposed to know 6v was + ground when I was 12? That was before I was born!

The starter worked right. My nephew drove it and didn't tell me the light was on. I only glanced at it tonight and the headlights seem weak but work. I'll post results if I get to it tomorrow.

rrobert · Apr 28, 2012

I found a plug with 2 black wires coming out of the engine shroud. I am getting 36 V AC from there. Next to that connection looks like some kind of resistor or diode with a white wire. Not sure what that is for. The battery starts at 12.7 V DC when off. When I start it and run it full throttle, it slowly creeps up from 12.2v to 13.6v DC. It does have a voltage regulator/rectifier under the dash. The wires are in a cloth loom and I can't see where everything goes. There is a fuse from the voltage regulator to the ignition(12V direct). I pulled the fuse out. The regulator side appeared to be 36 V DC. The other side was 12.7V DC. I put the fuse back in and both sides were 13.6 v DC.

The battery light is still on. I am guessing it is charging.

Anyone have a source for better wiring diagrams?

Thanks,
robert

Kawasaki 540 charging help

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