Blowing Headlights & Sputtering Under Throttle. Voltage Regulator or..?

[tooBUELL4school]

I went for a ride yesterday and after about an hour of normal riding, the bike started sputtering while under steady throttle (at about 3k RPMs in 4th I'll give a little more throttle and the bike would bog down a little then sputter and hesitate - no CEL or anything). I pulled in for a quick inspection and to gas-up and noticed my headlights had blown. I picked up 2 more bulbs and headed home to replace them. I checked the bulbs worked, then headed back out. After about 10 minutes I started having the sputtering issues again (3 & 4th gear around 3-4k RPMs but would go away when I had it pinned) and the bulbs had blown again.

Previously I had done the headlight mod so both lights are on when high beams are on and soon after I did that, I had issues with the voltage regulator connector which I removed and spliced the wires together. I haven't had any other issues after that until now.

Is this the voltage regulator going bad, from the headlight mod, something else? Any help or input is greatly appreciated.

Thanks

 

[BuellyBagger]

3-4k would likely be peak charging rpm, so VR is possible culprit. Test what it's putting out... should be just under 14 volts max. At the battery

Yeah brain farts should be over 14 running....

 

[Cooter]

What the heck do you mean by: "I had issues with the voltage regulator connector which I removed and spliced the wires together." The "77" connector from the stator?It's hard to tell, I don't even know what bike you ride

Type of bike notwithstanding, Buelly is right. Start the bike with a voltmeter on the battery and rev it to 2500 RPM. You should have approx 14.7 volts, but not much more than that! If it's over 15, replace the VR.

 

[tooBUELL4school]

It's an '07 xb12 stt. And yes, the 77 connector - sorry I couldn't find the thread with the name of the connector and I couldn't remember it.

 

[user_deleted]

double check the work you did behind the front pulley cover. if it is pristine with nothing shorting out and no "rub-thru" on any of your work then in fact it is the VR. a fautly one will typically blow the battery fuse but not always.