Strong burning smell or visible melted insulation near the alternator or wiring harness.
Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
Possible Causes
How to Fix / Troubleshooting
Safety first: Immediately shut down the generator and open all breakers. Do not touch hot or melted components.
- Visual inspection: After cooling, inspect all main output cables, lugs, and alternator leads for discoloration or melted insulation.
- Tighten connections: Tighten any loose lugs to the torque specified by Pulsar.
- Replace damaged wiring: Any burned or brittle wires must be replaced with the correct gauge and insulation type.
Because overheating may indicate internal alternator faults, have the alternator tested by a professional before returning the unit to service.
Repair Difficulty
Required Part
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