Thread: urgent. headlight voltage issue even after new battery and rectifier

I was blowing headlight bulbs and just got a new battery installed today (SLA type) and installed a new type rectifier:

*RECTIFIER CT70 KO THRU K2 (49G)

However, my issue did not change my headlight voltage problem. At idle I have 5.8-6.2 V, but as the RPMs increase towards WOT the voltage increases to 11-13V....which is the same problem I had with the old battery and factory rectifier.

I just had the engine out last weekend and cleaned up the coil and cleaned and tested all grounds.

I have gone through the electrical system and have no shorts and the ignition switch is grounded fine.

I cannot ride it on the road in Colorado w/o the headlight working

Any suggestions of what else to check?

I looked at the electrical diagram:

http://www.rnrfabrication.com/Wiring...%20DIAGRAM.pdf

Your headlight is not connected to the battery or rectifier. i.e. If you turn on the key to position 1 or 2 only the tail light, horn and neutral light should work. The headlight and highbeam indicator only operate when started and run off the alternator. Check if the Black and yellow wires are crossed in the alternator, this is the only item I can see. I'm sure you've already checked these. This is a real stumper.

Good Luck