Re: Voltage Regulator and Generator Troubleshooting Help

Posted by Fish'n Jim On 2016/4/10 21:14:58

Other than having an auto electric shop (or Auto zone) check it out with some diagnostic tools, not much from 2000+ miles away one can see. i.e. bench test gen, reg, and batt. If they're good, then the wiring is suspect.
If you insist on DIY.
You didn't say if you're watching the charge/discharge gauge or using VA meter to determine charging? You really need to measure amps not just volts. Need a field ammeter for that.
I agree with HH and others, the regulator (case) has to be at base voltage, so it won't work "right" on the fender cover with just the terminals jumped. I think there's a "ground" terminal/screw for that, but it's been two years, since I 6 volted. That's NOT the "Batt" terminal that powers the coils. In 6, you have to think + - backwards.
The gen will output more or less linearly based on rpm, that's why there's a "regulator". If it charges at too high a voltage, like 18, it'll make the lights bright and "burn" the battery. (So that's a clue) But the regulator only intermittently starts and stops the flow to the battery based on voltage. That V lo and hi can be controlled by the adjustment of the contacts. So a smart guess it's in the regulator and the wiring of it, since you appear to be getting output from the gen. or your battery would be dead by now.
Have to be orderly in troubleshooting.
Check the battery with nothing connected for voltage, first. Better to test with a battery strength tester. Should be ~6.2 if it's charged up. If first number is something else, either it's bad or needs charged. Correct that first, then you'll know it's not the battery. There has to be good voltage to the regulator or it won't work properly.
Then you can swop out the regulator with one known to work but that won't fix a wiring issue. You have to "polarize" the field again if you take the regulator off. I'd disconnect the "unnecessary" wiring and only work with the engine wiring to make it simpler. That's how I did it to get my motor started/functioning. Then as you put back you can "ring out" each circuit for faults.
You can easily see why they got away from 6V, gens, and regs. They work good, but not everyone can make them so.