Before tearing everything apart, I'm just familiarizing my self with the electrical components of my bike which look like a 2 year old wired it. It has never charged since I bought it. Tried a known gennie and new regulator and still no go. I've only now begun to spend any real time on it as I have been messing with issues with my other scoots. One thing I notice in the wiring diagram is a wire going to ground on the crankcase bolt? See attached pic where pencil is pointing, and no I did not write all that stuff on the diagram.

The regulator is isolated from the frame with the rubber grommets, (3 locations). Is the regulator supposed to have a ground connection????? I can easily run a wire to a crankcase bolt but where would it go on the regulator?

 

I am not familiar with that mechanical regulator so someone else will have to chime in. It might help to state the year and model of the bike, although it might not help much if it is really messed up wiring

 

My frustration with the wiring is that there are lots of unnecessary splices, wires unhooked going to nowhere and crappy routing and goofy connectors, etc. It is a 1970 XLH, sorry, I usually put that bit of info in. I'm going to eventually rewire it but wanted to enjoy it for the summer and tear everything apart in the fall as weather shuts down. With it not charging, my rides are limited to an hour or two with lights off. Very curious on the ground thing in the wiring diagram. It would be easy to go Cycle Electric but I'm trying to keep it somewhat period correct.

 

Here's some electrical trouble shooting threads which may be helpful as you go along ...

Ironhead Charging System Checkout
http://xlforum.net/vbportal/forums/s...ad.php?t=39146

Start System Testing
http://xlforum.net/vbportal/forums/s....php?t=1610248

Ironhead Voltage Drop Testing
http://xlforum.net/vbportal/forums/s....php?t=1608465

1977 generator brush inspection (with details and pics)
http://xlforum.net/vbportal/forums/s...d.php?t=589224

Ironhead How to Bench Test a Solenoid, pic & vid
http://xlforum.net/vbportal/forums/s....php?t=1525907

Ironhead Refurbish Starter Motor
http://xlforum.net/vbportal/forums/s....php?t=1718915

 

Excellent Mick, the Ironhead dudes can always count on you. Retiring early but will check those posts out tomorrow. I know it's not complicated but I like having things work the way they're supposed to.

 

an original harness is available and cheap if you consider the time you will spend on the rotted and pieced incorrectly the one you have - the day after you install it you will think why was i going to fix the old one again like someone else did when i know better

a stone original bike we leave the original regulator in place with fake wiring and install a generator end cap electronic unit and call it a day

 

John, somehow in the back of my mind I kinda knew I'd end up with a CE gen and reg, less trouble. Great links mick, excellent info. Had a '59 pan for a while and I did that switch to CE, it moves the regulator to the front, I have heard that having the regulator behind the motor subjects it to a lot of heat.

 

All regulators require a good ground mechanical and electronic. the mechanical with the rubber grommets has a short flexible wire that goes under the reg and over the reg bolt.

 

For the electronic regulators I always provide an extra ground, a wire that runs from a screw threaded into the back of the unit and running to an engine or frame bolt.