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Bill, for now, Im kinda thinkin along the same lines as JS, I wonder just how well the gennys is charging?? When running open not loaded Id expect the gennys output to be much higher then the 6.3, but when coupled up to a load (battery n lights n igniton etc) thats the true test and when it needs to maintain a voltage HIGHER then the battery to charge it. It needs the energy to raise the battery voltage to the 6.5 to 7 or so range to charge it, NOT put out 7 volts unloaded but drop to near battery voltage when coupled up to it. First thing Id do is by pass the VR functions to see just how well the genny charges then at the max possible charge condition. To do that dead ground the gennys Field post to the case n see how many amps she charges then????? ?? If its still low I suspect either the genny is weak,,,,, ,or the belts loose,,,,, ,,,,,or the genny dont have a good frame ground. If it charges MUCH higher then (with gennys field dead grounded), that tells me the genny is okay so the problem is either, the VR,,,,, ,,, or the wire from Field on genny to Fld on VR is bad,,,,, ,,, or the VR isnt well grounded to the genny. This assumes the battery itself is good and capable of accepting a charge, is it okay and/or has it been load tested????? ? If its a three brush genny and you convert from a cutout relay to a VR, I set the third asjustable brush to the MAX charge position which is as close as possible to the other brush next to it. If its far away that limits the gennys output. JS had good tips on basic genny maintenance, the commutator must be clean n bright, the brushes not worn too low and the brush hold down spring assemblies need to be clean n free so they hold the brushes tight down against the commutator. Let us know John T
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