BURNING OUT HEADLIGHT BULBS

[John W. Rymark]

Hi, need some help.

My Indian 741b started blowing headlight bulbs. One good rev up to speed and the headlight bulb burns out.

Background, it's a brand new generator, rebuilt by Jerry Greer Engineering (experts on all Indian items). I got the generator and will be using the bike mostly around town, parades, displays. So I decided to kick up the generator output a bit to ensure charging at low speeds. The third brush regulates the generator output through shunting more or less magnetic flux. Third brush pushed toward the rear of the bike, lower output. Third brush pushed forward, more generator output. I pushed it slightly forward from minimum. Started blowing headlight bulbs, quick. Just a couple revs up off of idle and the bulb would be burnt out. So, pushed the third bruch back, just off of minimum (as far back as it would go). Seemed to o.k. Bulbs seemed to be o.k.

Took her for a ride a couple minutes ago and came up to speed. Stuck my hand out in front of the light and no light. Switched to low beam. A couple revs and low beam burnt out. In Illinois, you've got to keep your motorcycle headlight on while ridding. No light is an open invitation to a ticket.

I worked in digital and automated control, computer systems, interfacing. This circuit is just too simple. It's really getting to me. Thought of a resistor to reduce the current flow, drop some voltage (share a portion of the voltage and current with the headlight). Also thought of a capacitor in parrallel with the bulb to reduce current and voltage spikes. Also thought that perhaps I should clean off my generator to frame ground ends.

Any ideas out there?????

[Michael Browne]

Hello John,

Have you spoken to Greers?? I would start there first and get their advice on how it is they set it up.

Good luck

[John W. Rymark]

Michael, yes and Todd at Greer's has been very helpful. He's suggested reflector, lamp base, headlight bucket to frame ground. I'll do those. I observed that my battery post negative to frame is a bit smaller diameter that the rest of the bike wires. Only had that gauge in black. Will go with larger diameter battery terminal to ground, perhaps reduce standing voltage at battery terminals. Will most likely also order a couple bulbs from another source just to see if who I bought them from and I got a sub-standard batch. Thanks.

Greer's was great help and provided superb parts during my 741b restoration. Met Todd recently at Wauseon Ohio meet when I brought him my CDE engine for rebuilding. I've since received a very professional parts list and quote. Customer service, tech assist, and all the way to the top, good people with Indians at Jerry Greer's. Sorry I haven't sent you CDE photos yet. Will do soon.

Hope your CDE is coming along. I also met Iver of Kiwi at Wauseon. Another gentleman. Iver finally bought after several years of pursuit a CDE by serial only a couple hundred after mine. I suspect they were both made in the first three months of 1945 production (October, November, December 1944). Very nice complete bike put in circa late 40's or 50's trim (seat, more chrome etc.), retaining its very rare original open fenders, as mine. A tremendous acquisition.

I intend to take my time and savor the CDE restoration, but it will take me much less time than the 741b since I've paid my dues in learning a bit about Indians.

Will email. Thanks again.