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GREG, Sounds like you are doing all the right things! Good work! I have done all those things myself & have a good starting & good charging 6V TO-20 also, even on those cold February mornings! Now the bad news.... your generator is only rated for ~12A output, and that's at full throttle. If you add-up all your electric demand, with your lights ON, your probably around ~11A with 25W headlights. I have EXACTLY the same problem. I also have a rear work light. I can't run all three lights at the same time or I'm discharging the battery. I was having trouble discharging the battery with just the headlights unless I ran the engine at full speed. You CAN adjust the output on your stock 3 brush generator to increase the amps a bit, that should get you to where you can run your headlights okay, as long as your not trying to run 50W bulbs. One of the generator brushes can be adjusted back & forth in the generator housing. Take the band off your generator and find the adjustable brush (has a slotted mount & hold down screw), adjust the brush... I don't recall which way now. The instructions for adjusting the genny output is not in the service manual, but it is in the original Fergy user manual. Make an adjustment, run your engine & watch your amps under load, if it's worse, you then adjust the brush the other way. There is no adjustment for the regulator to increase amps at full load, about all you can adjust on those is cut-in & out volts. You just need more power output from your generator. That is my biggest complaint about my 6V system, I'd like to have super bright halogen lights to light-up the night, run a 12V sprayer pump, and install one of those whimsical 12V air horns that plays a tune... can't do that stuff with 6V. George
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