Note

Before making adjustments or servicing regulator, identify regulator by number stamped on regulator base, or mounting bracket, then refer to table Fig. 51-1 which contains service information for desired regulator. Delco Remy Bulletins listed in table may be obtained from a Delco Remy service station or the Harley-Davidson Motor Co.

B. TESTING CUTOUT RELAY UNIT CLOSING VOLTAGE (THE SAME CONNECTIONS ARE USED AS IN TEST A (FIG. 51-2.)

1. Turn field control variable resistor to open position.

2. Operate engine at 1500 RPM (approximately 30

3. Slowly turn Field Control knob toward direct position to decrease resistance in field circuit. Voltmeter reading will increase slowly until cutout points close. Closing voltage will be highest voltmeter reading before meter pointer "kicks" to read battery voltage. After cutout points close, ammeter will indicate a current flow.

If closing voltage is not within specifications (See Fig. 51-1) adjust setting according to manufacturer's service bulletin. (See Fig. 51-1.)

C. TESTING VOLTAGE CONTROL UNIT SETTING (FIG. 51-3)

1. Remove battery wire from regulator battery "BAT" terminal. Connect a 1/4 ohm resistor (not less than 25 watts) in series with the removed battery wire and the regulator battery "BAT" terminal.

2. Connect the positive lead of a voltmeter (0-15 volts) to the regulator "BAT" terminal, connect the negative lead to ground.

3. Remove wire from regulator field "F" terminal and connect a 25 watt variable resistance Field Control in series with the removed wire and the regulator field "F" terminal, turn control knob to direct position (no resistance).

6 Volt Regulator - Operate engine at 2000 RPM (approximately 40 MPH). Turn field control resistor knob to "Open" position then to "Direct" position to cycle regulator. Check voltmeter reading. Reading indicated on voltmeter is voltage regulator setting.

12 Volt Double Contact Regulator - Operate engine at 2000 RPM (approximately 40 MPH). Turn field control resistor knob to "Open" position then to "Direct" position to cycle regulator. Check voltmeter reading. Reading indicated on voltmeter is the voltage regulator setting of the upper contacts (shorting contacts). Voltmeter reading should be within manufacturer's specifications (See Fig. 51-1). Maintain engine speed, slowly rotate field control resistor toward "Open" position to increase resistance until voltmeter reading drops slightly and then remains steady. This indicates the voltage setting of the lower contacts (series contacts). The voltage difference between the settings of the two sets of contacts should be within specifications (See Fig. 51-1).

If voltage readings are not within specifications, replace regulator or service and adjust settings (See "Servicing Regulator").

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Never ground the 12 volt generator or regulator field terminal while these two units are connected and operating. This will burn up the upper set (shorting set) of contacts of the voltage control unit.

D. TESTING CURRENT CONTROL UNIT SETTING ON 3 UNIT REGULATORS (FIG. 51-4)

1. Remove battery wire from regulator "BAT" ter -minal and connect to negative lead of ammeter (0-30 amps). Connect positive lead of ammeter to regulator "BAT" terminal.

Figure 51-4.

2. Connect positive lead of voltmeter to regulator battery "BAT" terminal and negative voltmeter lead to ground.

3. Turn on light and connect additional load to the battery to drop the voltmeter reading to one volt below voltage regulator setting.

4. Operate engine at 2000 RPM (approximately 40 MPH) and note reading on ammeter, If reading is not within regulator specifications (See Fig. 51-1) replace regulator or adjust according to manufacturer's Service Bulletin.

GENERATOR SYSTEM - WITHOUT BATTERY (6 Volt)

Covers 1964 and earlier Sportster Model XL CH. A. TESTING THE GENERATING SYSTEM (FIG. 51-5) NOTE

Make all tests with light switch in off position to prevent possible light burnout.

1. Connect an ammeter and 1-1/2 ohm resistor in series between regulator terminal marked "GEN" and ground. (Use regulator mounting bolt for ground.) Disconnect "F" terminal lead at the regulator to open the generator field circuit.

2. Start engine and run at slightly faster than normal idle speed. If ammeter shows any current flow, generator field is grounded internally or in wiring harness, and generator repair is necessary. If there is no current flow, proceed to make the following checks.

3. With engine running at idle as before, momentarily ground the disconnected generator field lead by touching it on the regulator mounting bolt. If ammeter does not show any current flow, the generator field circuit is open, or the generator armature circuit is at fault, and generator must be repaired. If ammeter shows sudden jump in output, the generator is functioning normally, and trouble is located elsewhere.

4. Reconnect "F" terminal lead to regulator. Regulator can now be checked to determine if it is functioning properly. Make regulator Tests B. C and D.

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