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  #1  
Old 7th September 2011
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Default Generator light stays on 1981 ironhead

Hi everyone. My generator light just started staying on constantly. Before, the light would come on at a low idle and when I would rev the motor it would go out. Now it just stays on. I haven't ridden it since because I'm afraid the battery isn't charging. The generator is pretty new, but the voltage regulator isn't. Could it be the voltage regulator? When I was in sturgis I noticed the headlight would go from dim to bright at night also.
Thanks any help is appreciated.
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Old 7th September 2011
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it could be the regulator.. but you can never know for sure if you don't measure with an multi meter..
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  #3  
Old 7th September 2011
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Could be either genny or reg. As said, you'll need a meter to find out.

Great info./tests here. I had the same problems earlier this summer.

http://xlforum.net/forums/s...ad.php?t=39146
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Old 7th September 2011
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I got tired of screwing around with the Gen/Reg crap and went with the integrated unit from JP cycle on the Iron head, No more problems.
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Old 8th September 2011
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Quote:
Originally Posted by Jmcnam11 View Post
Hi everyone. My generator light just started staying on constantly. Before, the light would come on at a low idle and when I would rev the motor it would go out. Now it just stays on. ...
The brushes are sticking in the generator. Easy fix.

Remove from bike [2 electrical terminals left side, two bolts right side] tip outer end down toward 5:00 o'clock, wiggle it out.

Dismantle the outer end; it will be filthy inside so spray inside with electrical contacts cleaner.

Test brushes and brush springs with your fingers - they should work smoothly; if not ask here about how to fix them.

Measure the brushes - should be > 1/2"; if not buy replacements.
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Old 8th September 2011
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Default genny/ohm question

with all wires disconnected, ohm meter shows both A and F poles are grounded to the genny housing. is this correct, because i don't think it is...
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Old 9th September 2011
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Both terminals should have insulating bushings part number 5911 outside the case. One, i do not know which, needs an insulator 31098-58 inside as well. No harm done if both are insulated.

Be sure to do only the tests from the Sticky and from the factory service manual. Do not experiment unless you do understand the electrics of how the gen works.

External insulators ...



You can see the head of the terminal bolt, and the spade terminal behind it. I believe that there should be a thin [cardboard?] insulator behind one of the spade terminals ...


Last edited by IronMick; 9th September 2011 at 02:48..
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  #8  
Old 9th September 2011
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in my blurry mind, it would have to be the single wire that is the ground and doesn't warrant an insulator, as the green wire connects to it. i am taking your tip and insulating them both with washers made from a styrofoam plate. thanks again Mick.
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Old 9th September 2011
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Neither of the wires at the gen is a ground. The green is output to the regulator. The tan wire[s] run to the gen light and the reg.
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Old 9th September 2011
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o wise and helpful one! rebuilt it this morning, and the green wire post was not insulated but the tan was. now the tan is not grounded to the gen case or the green post as it was before i started. i had a weak spring on one of the graphite blocks, so i made a shim to go behind it to buy some time, then i'll replace the springs and blocks all around. thanks again.
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