Testing Cutout Relay Unit Closing Voltage

Make same connections as in previous Test C, except connect battery lead "B" of tester to 1-1/2 ohm connection on side of tester.

1. Turn load control to "Direct" position.

2. Turn field control variable resistor to "Open" position.

3. Operate engine at 2000 RPM (approximately 35 MPH).

4. Slowly turn field control variable resistor toward "Direct" position while observing the voltmeter. As resistance is decreased in field circuit, voltage will rise.

Observe highest voltmeter reading before voltmeter pointer kicks back. Repeat operation several times, each time returning field control to "Open" position. Highest reading observed is the cutout relay closing voltage.

If closing voltage is not within specifications (see 51-1), replace regulator.

Figure 51-14.

Figure 51-13.

Figure 51-14.


Two tests are required:

1. Testing regualtor voltage setting under load.

2. Testing regulator voltage setting under no load. Testing Voltage Setting Under Load

1. Make connections as in previous Test D, except switch positive voltmeter lead to regulator "B+" terminal, disconnect tester battery lead "B" from 1-1/2 ohm connector on tester, disconnect field control lead from ground connection on motorcycle and connect this lead to regulator "DF" terminal.

2. Turn field control resistor to "Direct" position (no resistance in field circuit).

3. Operate engine at 2700 RPM (approximately 45 MPH).

4. Turn load control knob clockwise to load circuit until ammeter reads 10 amperes.

5. Voltmeter reading will be voltage setting under load.

Testing Voltage Setting Under No Load

1. Return load control knob to "Direct" position.

2. Turn field control resistor to "Direct" position.

3. Operate engine at 2700 RPM.

4. Voltmeter reading will be voltage setting at no load.

Both load and no-load voltage readings must be within specifications or regulator should be replaced. (See Fig. 51-1)

It is advisable to "flash" field coils whenever wires have been removed from 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 vi brate and burn. On battery systems, "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.

On systems without battery, connect negative lead of outside battery to generator frame and flash positive lead to generator "A" terminal. The momentary surge of current from battery to generator will correctly polarize generator.


Faulty operation of Delco Remy regulators may be due to one or more of the following conditions:

1. Contact points dirty, oxidized or pitted — To clean contacts, refer to manufacturer's Service Bulletin, (See Fig. 51-1)

After cleaning contacts, the air gaps and contact spacing must be adjusted. See Fig. 51-1 for information on the voltage regulator and cutout relay air gap and contact opening setting.

2. Ground wire broken (short braided wire between regulator base and mounting bracket).

3. Defective fuse (in holder near regulator).

4. Corrosion contamination on regulator internal parts.

After any faults have been corrected, regulating units must be adjusted according to manufacturer's Service Bulletin. (See Fig. 51-1).

Bosch regulator

Service or adjustment to internal parts of Bosch regulators is not recommended since contact spacing and air gaps are factory set. If tests indicate that the regulator is defective, it should be replaced.

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