Cub/Passport 6 Volt Headlight Voltage Regulator This unique device is the result of several years of owning, riding, and repairing Honda Cub and Passport motorcycles. This particular design is only for the 6 Volt version, which has a nasty habit of blowing the headlight bulb filaments if the battery is electrically disconnected, missing, or for any reason is unable to accept proper charge. The 6 Volt Cub/Passport headlight is powered directly from the engine stator with AC power. The Pardue Brothers have designed and tested this device to destruction, and it has earned our seal of approval. We hope it rates as a quality item that Soichiro Honda would have approved of. While the device is simple to install, we recognize that not everyone has extensive wiring experience. These instructions will guide you step by step to make the installation. Thank you for your business.
Step-by-Step Installation Instructions for the Cub/Passport 6 Volt Headlight Voltage Regulator No More Blown Headlight from OverVoltage The 6 Volt AC Regulator for the Cub Part Number 6VACRCUB
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Step 1 Remove Headlight Bulb and Trim Ring Assembly to dash lamp high beam indicator Disconnect the Blue Wire from Headlight Bulb to Dash Lamp High Beam Indicator
Step 2 Disconnect High Beam Switch from Headlight Bulb to handlebar high beam switch Disconnect the Blue Wire from Headlight Bulb to High Beam Switch
Step 3 Disconnect Low Beam Switch from Headlight Bulb to handlebar low beam switch Disconnect the White Wire from Headlight Bulb to Low Beam Switch
Step 4 Disconnect Chassis Ground from Headlight Bulb Remove Headlight and Put Aside to chassis ground Disconnect the Green Wire from Headlight Bulb to Chassis Ground Connector
Step 5 Disconnect Engine Stator from Headlight Switch to engine stator to headlight switch power feed Disconnect the Yellow Wire from Engine Stator to Headlight Switch Power Feed
Step 6 Using 12mm Wrench Remove Handlebar Bolts Lift and Slide Handlebar Forward The Voltage Regulator Fits Here
Step 7 Thread the Voltage Regulator Wires to the Right of the Speedometer Cable and Out Through the Headlight Bucket Thread the Wires
Step 8 Position the Voltage Regulator in the Handlebar Cup Reinstall Handlebars Locate Regulator
Step 9 Get Ready to Connect Wires from Regulator to Bike to dash lamp high beam indicator regulator to engine stator regulator to headlight switch power feed to headlight switch high beam regulator to headlight ground regulator to chassis ground to engine stator to headlight switch power feed Disconnect the Yellow Wire from Engine Stator to Headlight Switch Power Feed to headlight switch low beam
Step 10 Connect Voltage Regulator (Yellow Male) to Engine Stator (Yellow Female) from Voltage Regulator to engine stator Connect the Yellow Wire from Voltage Regulator to Engine Stator
Step 11 Connect Voltage Regulator (Yellow Female) to Headlight Switch (Yellow Male) to headlight switch power feed from Voltage Regulator Connect the Yellow Wire from Voltage Regulator to Headlight Switch Power Feed
Step 12 Connect Voltage Regulator Ground(Green Male) to Bike Chassis Ground (Green 3-Way Female) to bike chassis ground from Voltage Regulator Connect the Green Wire from Voltage Regulator to Chassis Ground
Step 14 The Regulator is Done. Re-Install the Headlight. Connect Voltage Regulator Ground(Green Female) to Headlight Ground (Green Male) to bike chassis ground from Voltage Regulator Connect the Yellow Wire from Voltage Regulator to Headlight Switch Power Feed
Step 15 Re-Install the Headlight. Connect Headlight Low Beam (White Female) to Switch High Beam(White Male) to headlight switch low beam from Headlight Low Beam Connect the White Wire from Headlight to Headlight Switch White Low Beam Wire
Step 16 Re-Install the Headlight. Connect Headlight High Beam (Blue Female) to Switch High Beam(Blue Male) to headlight switch high beam from headlight high beam Connect the Blue Wire from Headlight to Headlight Switch Blue High Beam Wire
Step 17 Re-Install the Headlight. Connect Headlight High Beam (Blue Female) to Dash High Beam Indicator (Blue Male) to headlight high beam dash indicator lamp from headlight high beam Connect the Blue Wire from Headlight to Dash Lamp High Beam Indicator
Step 18 Re-Install the Headlight. Tuck Wires Behind Headlamp Bulb Assembly Reinstall Headlamp Screws. The Regulator will Prevent Excessive Volts from Blowing Headlight Bulbs. Bulbs will Still Blow from Vibration and Other Normal Causes. If you have any problems or questions please review the instructions and insure you have done a good job wiring and installing the Voltage Regulator. We are always available to assist you via email. The Cub/Passport Voltage Regulator is Made to Last. Designed and Manufactured in the United States of America by Americans.