Honda built the Cub without a Voltage regulator, instead relying on the electrical load of battery and lights to limit Voltage. If for any reason the battery is not viable or missing, lighting Voltage will skyrocket. Bulbs blow, especially the expensive headlight bulb. Once one bulb blows, the rest will blow in rapid succession.
For some unknown reason, with age some Hondas begin producing excess headlight Voltage. Its a mystery why, even after unwinding several stators. This happens on bikes that have been just fine. Even with a viable battery and all bulbs intact, the Voltage is suddenly too high.
After years of working with these problems, Jon designed a special Voltage regulator to control the excess Volts and prevent headlight and bulb failures. The device is ruggedized, waterproof, and plugs in. Installation is simple. Wires and connectors are color matched. The regulator plugs in without modifications to your Honda’s wiring harness, and fits under the handlebar cover.
July 12, 2014: Eagle-Eyed customer Wayne caught a ground wire error in the instructions… thanks!
The 6 Volt Cub/Passport headlight is powered directly from the engine stator with AC power.
The Pardue Brothers have designed and tested this device to destruction, and it has earned our seal of approval. We hope it rates as a quality item that Soichiro Honda would have approved of. While the device is simple to install, we recognize that not everyone has extensive wiring experience.
The instructions will guide you step by step thru the simple installation inside the handlebar cover.