Pulsar Excessive Brush Arcing

Visible sparks or arcing at the generator brushes or slip rings (on brush-type Pulsar alternators).

Advertisements

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.

Advertisements

Possible Causes

Worn brushes, Dirty or pitted slip rings, Loose brush holder, Overloaded alternator

How to Fix / Troubleshooting

Safety first: Turn OFF the generator, disconnect the battery, and wait for all rotating parts to stop before opening the alternator end cover.

  • Inspect brushes: Check brush length and spring tension. Replace brushes that are worn below the Pulsar minimum specification.
  • Clean slip rings: Lightly polish the slip rings with fine emery cloth to remove carbon buildup.
  • Tighten brush holders: Ensure the brush holders are secure and properly aligned.

After reassembly, run the generator under moderate load and observe. If arcing continues, the rotor or AVR may be damaged and require professional service.

Advertisements

Repair Difficulty

Hard 4/5

Required Part

Pulsar Alternator Brush Set
Check Price on Amazon

We may earn a commission from links on this page.

Advertisements