Here is the story:
Being the Safety Conscious guy that I am, I installed a High-Beam Head Light Flasher, for day-time use once the warranty was up (3 yrs).
Works great and it automatically stops flashing at dusk. Awesome so far, BTW head-on collisions have been avoided in this manner.
About 2 yrs after Flasher installation the RLU decides to quit because, after all, when the Head-Light Flasher Operates the RLU senses
this as a bad High-Beam and turns on the low-beam, so High-Low, High-Low we go. Well, now Only High-Dim-High-Dim.
I bought a good used RLU but didn’t install because it would just go bad again due to the Flasher.
Well, three years later the Voltage is lower while the bike is running then when I first placed a freshly charged battery in there.
With the Head-Lamp and Tail fuses pulled than I can get a decent voltage, but only 13.5V @ 4K RPM, with fuses in 12.78V @ 4K RPM.
The R/R gets hot, the Generator wires get Hot, the R/R fails “COLD” Meter Resistance Checks. I suspect a Diode got ‘tired’ of modulating
In rhythm with the Surge/Sag that the Head-Lamp flasher was causing (could also notice tail light flickering in rhythm).
So, the Big Fix: Replace the R/R, install the used RLU, Beef-up the Generator Wires, Install a LARGE Electrolytic Capacitor and go.
The thought here is that there is less of a Surge/Sag when you go from High to Low Beam during Flash. The lack of RLU caused a much higher
Surge/Sag potential working the R/R Diodes to death… Literally. The R/R is a completely sealed unit beyond economical repair, New $119-168.
OEM Head Lamp is 60W (5A) High Beam and 55W (4.58A) Low Beam: A fluctuation of .5A with SLU working instead of 5A on/off without.
Do you guys have any thoughts and/or experience with this?