96 Ultra Mod blowing headlight.

[Powderstash]

I picked up a 96 Ultra mod on a swap with my blown up RX-1 this fall and I have been working on it non stop. I finally got all the bits parts and pieces together from multiple wedge bodies (notice the 94 XLT hood and nosecone)and it's ready to rock except one thing. I keep blowing the headlight as soon as I start it. I have a new wiring harness installed. Seems like the voltage regulator is no good. Weird part is, I can't find the voltage regulator on it. Where is it and which cat reg should I replace it with?

Thanks in advance - stash

 

[theultrarider]

It's in the footwell area on the clutchside. Yes, that will cure your issue. And any of the 90's cat 2 wire regulators should work fine at half the cost of a poo and last 10x's as long.

Wait, it may be on the otherside, been too long and been into too many other sleds since. Any how, it's near one of the two footwells. More I think about it, pretty sure it's the chaincase side on a wedge. I was thinking edge. Both are junk from poo.

 

[retiredpop]

It is on the chaincase side footwell. If you used the wiring harness from a wedge or gen II then there should be a yellow wire in that area with a bullet connector for the regulator.

 

[Powderstash]

Thanks guys. I will look into it and hopefully that works!

 

[DanB]

Also, be sure to check the ground wires at the regulator. You should find one or more brown wires with a terminal crimped on and that terminal is fastened to the frame by the same hardware used to mount the regulator. I had a situation where the ground wires fatigued and broke at the terminal which prevented the regulator from functioning correctly (these are shunt type regulators). It blew out every light on the sled.

 

[Powderstash]

turns out the regulator was removed, thus why I could not find it!

 

[Powderstash]

update - still having issues. I put a new regulator on and a new bulb in and now I have no light at all. It didn't even light up an blow. Anyone tell what the voltage at the lightbulb should read? That's my next step and ordering a new bulb.

 

[mike_s]

System voltage on these older sleds should come back as about 12 volts A/C. That screws with alot of people, the system is alternating current, not direct curent. Make sure the wires are connected correctly, yellow to the regulator input and a black wire from the reg to a good CLEAN ground. There is a chance that your reg was DOA, ive had a few of those.

 

[DanB]

I'd recommend also testing the unregulated voltage. Unplug the connection between the harness and the alternator but leave the ignition connector plugged in. Set your meter for AC as Mike indicated and connect it between the yellow and brown wires at the plug coming from the alternator. Start the motor and rev it to 3000 RPM. You should read 15 volts or more (probably 20 or more) as the Ultras had higher wattage alternators.

 

[Powderstash]

I'd recommend also testing the unregulated voltage. Unplug the connection between the harness and the alternator but leave the ignition connector plugged in. Set your meter for AC as Mike indicated and connect it between the yellow and brown wires at the plug coming from the alternator. Start the motor and rev it to 3000 RPM. You should read 15 volts or more (probably 20 or more) as the Ultras had higher wattage alternators.

Well, that is another issue. Being a mod, the previous owner removed the ignition switch as well as the regulator. It is hot wired. I only replaced wiring to the hood. Now I think it is is time to do the whole thing. I have all the wiring and a key switch. The thing runs great, just no lights