Cleaning copper wire ends clean can be done easily enough by pouring boiling water on the exposed wire end (NOT on the battery). Soldering all the wires together as a single solid wire is not recommended. The point of multi strand wires is to increase the surface area of the conductor, i.e. copper wire. This allows greater current flow. Still wondering about the lack of charge. If the wires are all good to the starter the starter will work. If there is a wire problem it must be between the battery and the generator or between the battery and the cutout or between the generator and the cutout. Perhaps check the resistance across the cutout when the contacts are closed, i.e. allowing current to flow through. If the cutout is working and the wiring is all good then you are almost certainly looking for a generator fault. Check the brushes and then check the armature and field coils. These two tests may help:
1). Always check that wiring and instruments (ammeter / voltmeter) are in good order and operate correctly.
2). Ensure that all connections are good, tight and clean.
3). Ensure that the battery is in a satisfactory condition and that the connections to it are tight and clean, especially the connection to Earth/Ground. There are basic tests to check generator operation:
Test 1): Disconnect leads from generator. Connect one lead of a Voltmeter to the Main (or D) terminal and the other lead to Earth. Start the engine. Run the generator up to approx. 3,000 rpm.
Result:
a).Voltmeter reads 2-4 Volts = armature and brush connections OK (6 and 12 volt systems)
b). Voltmeter reads 0 Volts = Check brushes are in good condition and make good contact with commutator. If brushes are good and reading remains at zero, the armature is defective.
c). Voltmeter reading rises with engine speed = short circuit between Main (or D) and Field (or F) terminals. Field coils defective.
Test 2): Disconnect leads from generator. Connect Main (or D) and Field (or F) terminals to each other. You can use an ammeter to do this. (The ammeter should read no more than two 2 amps. Connect one lead of a Voltmeter to the Main (or D) terminal and the other lead to Earth. Start the engine. Gradually increase engine to a fast idle speed.
Result:
a). Rising volts with rising speed and full scale reading at fast idle = generator is in good order.
b). 2-4 volts as engine speed increases = open circuit in field coils. Field coils defective. (6 and 12 volt systems)
c). 0 volts = grounded field coils or field connection. Repair connection and/or replace field coils.
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