Item #1: Read the article I wrote about generators/regulators in the Tech Tips section.
2. DO NOT remove battery cables with the engine running! it causes big voltage spikes that damage things. (Especially solid-state voltage regulators in self-contained alternators!) It's not good for mechanical regulators on generator/regulator systems, just not as deadly. I've seen spikes of over 100 volts from a 12 volt alternator.
To polarize the generator, remove the wire from the "Arm" terminal at the regulator, and touch it to the "Bat" terminal for half a second or so. You'll get a medium-sized spark. If you get a BIG flash, the armature is shorted, and it's time for a new generator. Reconnect everything, and start up. The voltage should rise to about 7 volts at the battery terminals at a fast idle if everything is working OK. If not, take the "Fld" wire off the regulator and ground it to the regulator base. Check the voltage with it grounded. Voltage should be above 7 volts, and should rise further if you rev up the engine. If the generator is charging that way, it's time to adjust or replace the regulator.
Jerry
