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SCHEMATIC DIAGRAM. SHOWING GENERATOR INTERNAL WIRING CONNECTIONS AND LOCATION OF FIELD COILS AND BRUSHES IN RELATION TO EXTERNAL CONNECTIONS (THREE BRUSH GENERATOR). THIS IS THE STANDARD GENERATOR NORMALLY SUPPLIED ON ALL MOTORCYCLES—ALSO APPLIES TO RADIO THREE BRUSH GENERATOR.

With one test point on "GEN" terminal, and other test point on relay armature, test lamp should light. If it does not, it indicates an open circuit in series (current) coil.

If relay passes above tests, and generator is known to be O.K., but points do not close, it is an indication that series coil is grounded, or voltage coil grounded prematurely.

It is not practical to disassemble relay for repairs. A relay worn or damaged beyond adjustment service should be replaced.

Cut-out relay must be grounded; theiefore, mounting screws musf be tight.

Current and Voltage Regulator

A current and voltage regulator is an electrical device that controls generator output, and is used with two brush generator only. Generator cutout relay, current regulator unit and voltage regulator unit are all mounted on one base.

It is a special regulator as concerns its adjustment for proper regulation of a Harley-Davidson generator. Therefore, a regulator adjusted for an automobile generator cannot be used for regulation of a Harley-Davidson generator, otherwise serious damage to generator will very likely result.

The regulator is properly adjusted at factory when manufactured. Unauthorized persons must never tamper with adjustments as special equipment is required to properly adjust regulator. Under ordinary circumstances regulator will need very little attention in service.

If, however, regulator does need attention it should be referred to United Motor Service (located in many cities throughout the U.S.A.) who is authorized to service Delco-Remy regulators.

The following checks can be made to determine whether or not the units are operating normally. If not, the checks will indicate whether the generator or regulator is at fault, so that proper corrective steps may be taken.

Connect an ammeter between battery positive (left) terminal and regulator terminal marked "BAT".

Fully charged battery and a low charging rate indicates that regulator has reduced output, as it should when operating properly.

Fully charged battery and a high charging rate indicates that regulator is failing to reduce output as it should; due either to a faulty regulator or generator.

High charging rate to a fully charged battery causes battery to gas and overheat, also produces high voltage in the electrical system which may cause armature, coil, breaker point and lamp bulb failure.

To determine if regulator is at fault, disconnect "F" terminal lead at regulator to open generator field circuit. If charge rate drops to zero trouble has been isolated in regulator.

If charging rate continues, generator field circuit is grounded internally, or in wiring harness.

A low battery and a low or no generator charging rate indicates a high resistance in charging circuit, or regulator or generator is faulty.

Check wiring for loose connections or frayed or damaged wires. High resistance resulting from these conditions will prevent normal charge from reaching battery. If wiring is in good condition, then regulator or generator is at fault.

Ground "F" terminal of regulator temporarily and increase generator speed. Avoid excessive speed for any length of time as generator output may be dangerously high and damage to generator may result.

1. If generator output does increase, regulator needs attention.

2. If generator output remains low with "F" terminal grounded, generator is at fault and should be checked further.

3. If generator does not show any output either with or without "F" terminal grounded, disconnect wire from "GEN" terminal of regulator and strike it against a convenient ground with generator operating at medium speed. If a spark does occur, cutout relay is not functioning to permit current to flow to battery. If no spark occurs, generator is at fault and will need further attention. See "When Generator Fails to Charge,"

CAUTION: It is advisable to "flash" field coils whenever wires have been removed from generator or regulator; or after generator or battery has been removed and is reinstalled. This is done to make sure generator has correct polarity. If polarity of generator is reversed, relay points will vibrate and burn. "Flash" field coils by momentarily touching a jumper wire between "BAT" terminal and "GEN" terminal on regulator, after all wires have been properly connected and before starting engine. The momentary surge of current from battery to generator will correctly polarize generator.

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