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  #1  
Old 27th September 2020
Doc308 Doc308 is offline
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Default Generator light q

The bike is a1969 XLH. The problem is that the generator warning light won't go out after the bike is started and running. This started today while on a ride. After I got home, I tested the battery and it seems fine--12.8v with the engine off and over 14v while running.This was after riding about 50 miles with the light on.

What could cause this---bad connections, something wrong inside of the generator? I know that one wire from the light goes to the generator terminal on the regulator. Where does the other one go? I know that it initially goes to #28 terminal on the terminal board. Where does it go from there? I find the diagram to be relatively unclear.
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Old 27th September 2020
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The generator light should be between the regulator and battery +. Easiest way to tell if it's the light or something else would be to disconnect the two wires you can find and hook the light directly to + and ground. It should light up one way but not light if you swap the connections. If it lights up both ways your diode is probably toast.

Edit: Note, I'm making some assumptions here since I don't have a '69 wiring diagram.
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Old 27th September 2020
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This thread (by IronMick) should be helpful:
http://xlforum.net/forums/showthread.php?t=39146

And maybe this one:
http://xlforum.net/forums/showthread.php?t=559976

The common junction point (#28) is fed power by the YELLOW wire from the Keyswitch Contact labeled I (for Ignition). The Keyswitch B Contact (for battery) is connected on the Battery terminal of the Regulator (which is also connected to the Battery, thru the main circuit breaker, by the Battery connection at the Starter Solenoid).

So, at the bulb:

::: you have a BLUE wire, which is monitoring the output of the Armature on the Generator (which connects at the GEN contact on the Regulator).

::: you have a GREEN wire which is monitoring B+ at the common Junction Point (#28).

If both the BLUE wire & the GREEN wire are supplying voltage to the bulb, the bulb should be OFF.

There is no diode (stock) for this year.

I don't know if the Sportsterpedia diagram might help you:
http://sportsterpedia.com/doku.php/t...69_sportster_h



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Old 27th September 2020
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As posted no diode stock, but if it has one, it has been rewired and could be the thing since it works but you have a light.
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Old 27th September 2020
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Default

The wiring on this bike is basically stock aside from my adding a starter relay to the system ( '69's came without relays). No diodes either.

So, it all of the connections are clean and tight, and the generator is charging, could the problem be within the generator itself?

Everything was functioning perfectly until yesterday when suddenly the light stayed on after starting up after a lunch stop.
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Old 27th September 2020
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Best is to uninstall, refurbish, reinstall the gen. To uninstall the gen see step 12 at the end of this thread...

IronHead Charging System Checkout
http://xlforum.net/forums/showthread.php?t=39146

Generator Refurbish
http://xlforum.net/forums/showthread.php?t=1718208
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Last edited by IronMick; 27th September 2020 at 16:13..
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Old 27th September 2020
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To add to what the others have already said, here's a wiring diagram for a '69 XLH. The genny light is #34 in the diagram (upper left corner, where the red and yellow lines meet. The red and yellow lines are for illustrative purposes only, they're not necessarily the actual wire colors.) The genny light has two wires coming from it. One wire is eventually connected via the red path to the battery + terminal. The battery is #14 in the diagram. The other wire from the genny light is connected via the yellow line path to the "Gen" terminal of the voltage regulator (#4). When you first turn the ignition switch (18) on, the red line will have +12 volts from the battery, but since the genny isn't turning and isn't putting any voltage out, the yellow line will be 0 volts, so the genny light should be on.

After the bike starts and the genny is spinning, if everything is working right, both the red and yellow lines should have +12 volts on them. Since there's no difference of electrical potential between the two wires of the genny light, no electrical current will flow through the light and it won't be lit up.

If the genny stops putting out 12 volts, the "yellow line" will no longer be +12 volts. It will either be a lower voltage or have no voltage at all. That will cause a difference of electrical potential between the two wires of the genny light, and current will start to flow through it, which will light it up.




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Old 27th September 2020
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Without a diode the light will be on any time there's a voltage difference across it. If the generator and regulator are working, this could mean an unexpected source of resistance somewhere in the circuit for the light. Possibly a loose or corroded connection, or a wire that's pinched or breaking internally. Basically I'm thinking the voltage at the Gen terminal is higher than what the light sees coming from the battery, so it's running in "reverse" instead of turning off.
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Old 27th September 2020
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Update: It turned out to be a bad connection at the light bulb itself.

Thanks everyone for the input and , as usual , the knowledge gained--much appreciated.
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