TLDR; You need to test with actual voltages experienced by equipment in field. Read why below.
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Originally Posted by thedrewski86
I'm getting closer to a solution on this, but I'm just not there yet. Here is what it's doing:
All these voltages are read with the engine running.
I am reading 14v across the headlamp fuse, regardless of a jumper wire being placed between the stator and the one yellow wire going to the junction box.
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Yes, let's take this in sequence
A. Power comes out of battery and goes across 30a main-fuse through
wht wire to ignition-switch.
- Ignition-switch ON, sends power out
brn wire switch to junction-box
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brn wire goes across headlight fuse 1st, that's why you're measuring 14v at headlight fuse. It's just sitting there waiting, not trying anything shifty...
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I am reading 0v coming off the blue/yellow wire coming out of the junction box with no jumper in place.
When I jump from a 12v source to the yellow r/r signal wire going into the junction box, it spins the starter motor. This seems to follow, given the wiring diagram.
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B. Without headlight-relay activation, you'd have no power coming out of junction-box on blu/yel wire.
C. Applying 12v to yel wire @ junction-box will have power going through headlight-relay activation-coil and then through starter-solenoid activation-coil and running starter. Similar to if you held down start-button... Starter-solenoid activation-coil provides ground-path for power going through headlight-relay's activation coil. If power is going through 2-coils in series, how much is each coil actually getting?
Why doesn't headlight-relay activate? There's power going through it?
You're skipping ahead. Measure actual conditions in the wild so you can replicate in lab setting:
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2. measure for AC on this wire as part of stator tests: A-B, B-C, C-A
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With engine running, measure AC volts across each pair of yellow stator wires:
A-B, volts = ???
B-C, volts = ???
C-A, volts = ???
These numbers will tell you everything you need to know to fix this.
If you've actually connected yellow stator wire to junction box, then headlight-relay may be 1st one we've seen fail. PM me address and I send you spare junction-box.
BTW - there needs to be bleed-resistor and capacitor on headlight-relay in junction-box...