Download PDF installation instructions here
This happens on bikes that have been just fine. Even with a viable battery and all bulbs intact, the Voltage is suddenly too high.
A viable battery takes a charge, and supplies power to a load, such as lights.
Honda built the CT110 with no Voltage regulator. The electrical load of battery and lights limits Voltage. If for any reason the battery is not viable, or missing, lighting Voltage skyrockets. Bulbs blow, especially the expensive headlight bulb. Once one bulb blows, the rest will blow in rapid succession. While the headlight is powered by a stator circuit separate from the battery charging circuit, the stator windings are interconnected. Each circuit regulates the the other, to a degree.
The CT110 dynamo has several AC power outputs . An electrically isolated output provides AC power for ignition. A complex group of interconnected windings provides dual AC outputs to power a rectifier. The resulting DC power charges the battery, which powers small lighting and the horn. A single output powers the headlight and HI beam indicator directly from AC power.
After years of working with these problems, we designed a special Voltage regulator to control the excess Volts and help prevent headlight bulb failures. The device is ruggedized, waterproof, and plugs in to the stock Honda wiring without any modifications. Installation is simple. Wires and connectors are color matched. The regulator plugs in without modifications to your Honda’s wiring harness, and fits inside the headlight bucket.
Excess Voltage is converted to heat inside the regulator. The regulator does not consume any power while the engine is running slowly. This is super important, because these old 6 Volt bikes do not generate enough electricity at low RPM to maintain headlight brightness. Once engine speed picks up enough to generate too much Voltage, our regulator smoothly kicks in just above 6.5 Volts to absorb just the excess Volts. The headlight receives full power, and the regulator automatically adjusts to absorb just the extra Volts. The heavy-duty regulator core is rated for 25 Amps, far more than the headlight stator can generate. The automated circuitry monitors the Voltage faster than the engine produces it, so you never notice it working as you ride.
The regulator circuitry is uniquely constructed. Motorcycles are tough on parts, we have seen many failed bits and pieces over the years, especially circuit boards. Off road riding is especially tough, as are single cylinder engines which may vibrate harshly at certain speeds. Vibration, humidity, heat, cold, freezing, shaking, pounding, jumping, landing, dirt, grit, water, dunking, gas, oil, grease, detergents, and probably more… tends to destroy any kind of electronics.
As technicians we have repaired and diagnosed many defective motorcycle circuit boards, so we set out to build something tougher, more battle-hardened. Cheaply built electronics we encounter today, are not up to the standard Honda set when these bikes were built. We hand assemble each regulator so the device operates without any solder. This involves crimping, wrapping, forming, and several other sturdy techniques that take a lot of time. After passing a functional load test, each unit is then fully soldered, and load tested again. The exterior is American-made electrical PVC conduit, custom machined inside and out. While its not pretty, it does function in harsh conditions It can survive hammer blows and still perform.
Encapsulation in solid thermal compound is not done to hide our work, its done to stabilize and protect it from abuse. We make stuff that will survive on our own bikes, and we are proud to offer our gear to you.
Built Strong to Last Long.
If Its This Good, Its From the Labs and Workshops of the Pardue Brothers