Paul and Mike G. both ventured good comments.
Paul began "Not exactly my question, since I was asking about the 12V version of the C70" and "whether the OP might have avoided problems with his battery. I would assume the 6V problems and 12 V problems are similar so that your answer would also apply to a 12 V C70?
You are correct, lack of a proper Voltage regulator affects both models.
Paul continues "Now, if I may open a larger can o' worms, what are the issues that affect the 6V bikes that pose problems for off the shelf VR's? Or will that answer take a book to answer? Please keep it to layman's terms as much as possible, I'm not an electrical engineer, I only know enough to get myself and others into trouble."
I'm a technician and inventor, not an engineer. At idle, Cubs produce low AC headlight Voltage. At idle DC Voltage from the rectifier is less than battery Volts, so the DC-powered brake lamp, tail lamp, dash lamps, horn and blinkers draw most of their Volts from the battery.
As engine speed increases, AC headlight Voltage and DC charging Voltage keep climbing. The total electrical load of the headlight bulb, battery charging, lamps and horn limit the maximum Voltage the system can reach. Maximum Voltage happens at high RPM cruise with only headlight, dash illumination and tail lamp lit, after the battery fully charges.
With clean electrical connections and good battery, any missing load - even the dash or tail lamp - allows Voltage to increase, straining the headlamp filament. A good battery "absorbs" the extra Volts at high RPM. Dirty or broken connections and/or a bad battery will allow the Voltage to skyrocket and nuke the light bulbs.
Mike G. commented "IIRC, the Euro bike use a special regulator/rectifier to change ALL the AC from the generator to DC and send it to the battery to power everything - the ignition, lights, etc. - unlike our AC/DC USA-Types. It's used in conjunction with a ballast resistor on the headlight circuit to protect the systems when the light is turned off (something we can't do in the USA).
That said, I would like to see exactly what the Euro model regulator does, and its connections. It very well COULD work on a USA-Type. It has to connect up with the same wires, clip the voltage at the right point, and have enough heat sink to do it continuously at full throttle without melting."
Got no wiring diagram for a resistor-equipped Euro Cub with a regulator. Anyone have a copy?
Mike G. is correct regarding the 12 Volt USA model.
I would accomplish the change as follows:
Rewire headlight switch to battery power.
Rewire original headlight power to rectifier circuit.
Replace rectifier with rectifier/regulator.
The rectifier/regulator used on the Honda Spree will suffice.
The resistor would not be needed for always-on headlight bikes.
A larger capacity fuse might be needed.
If the Ignition Switch or fuse shows signs of heating or duress, it would be simple to add a headlight relay and separate fuse.
The only real unknown is how the rectifier/regulator will handle the possibly unbalanced AC Voltage/Amps from the stator. Should be fine.
If someone wishes to try this, I will draw the wiring diagram.
Paul's 6 Volt Cub answer: Voltage regulators need more Volts going in than they put out. The 6 Volt Cub's low idle Voltage renders a regulator a blockade to power. 6 Volt bikes have been my focus for some time, and a clever new rectifier/regulator kit design is evolving on my bench. Will publish results when I have something good.
Jon Pardue
Sarasota, Florida
1970-73 C70 Honda Service Manual: http://tinyurl.com/6ebwtw
1970-73 C70 Troubleshooting Guide:
http://tinyurl.com/6ebwtw (scroll to sec.7.1 page 101.jpg)
1980-83 C70 Honda Service Manual: http://tinyurl.com/hu42c
1980-81 C70 Troubleshooting Guide:
http://tinyurl.com/hu42c (scroll to sec.18-1 page 170.jpg)
1982-83 C70 Troubleshooting Guide:
http://tinyurl.com/hu42c (scroll to sec. 20-28 page 205.jpg)
1980-81 C70 Maintenance Schedule: http://tinyurl.com/z4zn6
1982-83 C70 Maintenance Schedule: http://tinyurl.com/hw35c
More resources for C70 Passports and Cubs:
http://www.shlaes.com/Vehicles/Scooter.htm
http://www.velodrome.com/HondaC70/HondaC70.html
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