Clean the regulator mount point. It's not grounding. If the alternator is putting out, it has to be a ground issue.

I'm with Tom on this one. Unless the battery is connected to the output of the regulator it will not produce a voltage. Try connecting a wire directly from the battery to the regulator and you will find out the regulator is producing 13 - 14 volts. The regulator needs a load on it to work. A bad connection between the two and it won't work.

The regulator mounting point is clean as a whistle. Made sure of that before I installed it.

RL, You're suggesting I need to connect the POSITIVE on the battery directly to the regulator, not the negative? Is that right?

I think I get what you're saying about it needing a load(though I have to admit, it doesn't make much sense to me). Again, not an electrical guy.

Thanks.

Jbo

I see smoke on the horizon.

Here is the proper wiring diagram showing current flow from the regulator, be sure you have proper ground at the starter solenoid, clean the mounting tab for it, you should have a green (ground ) wire coming off the neg batt terminal going to the solenoid, then it jumps to the voltage sensor to ground it also.
Hope this helps

https://drive.google.com/file/d/0B9j...ew?usp=sharing

You need a connection from the output terminal of the regulator to the positive battery terminal.

OK. Jumped from the positive on the battery to the red DC wire on the regulator. Same 10.54 volts DC across the battery as before.

Checked from the red wire at the regulator (while jumped to the battery) and also got the 10.54 volts there, so my jumper connection was working.

Since I was there, I re-re-re-checked and still getting 29Vac from the stator to the regulator.

Still stumped.

Jbo

How fast are you running the engine?

Along with the jumper as you described above, you could try adding an additional jumper from the negative side of the battery to the case of the regulator just to rule out a possible flakey frame ground somewhere back to the battery.

Additionally, (I may have missed it) but have you tested out the battery? 10.5 volts sure looks like there could be a dead cell, and as others have previously pointed out, the load of the battery determines the output of the VR. You have a magneto ignition so that is not going to put any load on the battery. If the battery is only good for 10.5 volts, that all the VR will put out.

Just throwing out a few more thoughts, hope they help.

It might be possible that the stator is putting out 29 volts, but when you actually load it, by asking it to put out amps, it goes open
( broken wire) or to ground (shorted)

So I'm thinking while you have a hot jumper wire (+) from the battery, hooked to the output terminal of the regulator, and the engine is running 3600, check to see if you still have 29 Volts @ the 2 stator wires.
Do this by probing the terminals @ the regulator with the stator wires connected to it and the meter set on AC volts.
That test should tell if the stator has an intermittent problem while being asked to put out a charge.
-----About the only thing I can think of.:bigthink:

Agreed,a battery @ 10.5 V is dead.
It should not start the engine.:bigthink:
might substitute a good known battery from anything and give things a try.