I had a long response typed, and fat-fingered a key and erased it! Try cleaning the regulator points, but NOT with a file or sandpaper. Regulator points open and close with a slight wiping action, supposedly to be self-cleaning, and scratches on the contacts can cause them to stick. Use a clean business card, or a slice cut from an index card to burniush the points. Dosconnect the Battery wire from the regulator first, to prevent closring the cutout relay accidentally and causing a short through the generator. Use the card stock to scrub the contacts and remove any oxidation they might have built up from non-use. The cutout relay snaps closed and stays that way as long as the generator is producing more voltage than the battery, but the current and voltage regulator points vibrate several times a second as they perform their function. The voltage regulator (in line with the F wire) operates much more than the current regulator. It usually only functions for a short time adter startup while the generator is refilling the battery after the starting load is drained from the battery, or if a high constant drain such as a winch or other high current accessory is being used.
Jerry
