Generator avr

[landroverbob]

Probably obvious I'm not good with internet and forums etc but need some advice over a portable generator that I have in to try fix for an elderly neighbour. I service the motor frequently and it starts and runs beautifully it's a pretty old Honda EM1900, 12v/120v/240v. with a Sawafuji alternator used for her electric fence battery and barns. It's been banging out 300 v so I guessed it was the AVR. A like for like new one was over € 150 (I'm in rural france - europe) and she's living on her pension so beyond her means but I found one for a harbour freight generator AVR -universal application - of the same physical size and bolt mounting pattern and for the same output but the wiring ok to the brushes the colours are different to the four pin plug that goes to the stator etc and the wires on from that socket go out of sight - see pic. The connector plug is different but that's easily changed. I've spent a long time on the net looking at pictures and wiring diagrams but can't see what I need or can understand and I guess being Honda (I have several Honda classic trials bikes and have experience of their policy of making absolutely nothing easily interchangeable) want you to be only able to buy from them so can anyone tell me which color to which color I connect at the plug. Files attached - I hope.
lrb

 

[BillK]

Exactly which regulator did you buy ?

 

[The Cobbler]

James Condon on you tube does a lot of videos on generators, he may have some videos on the avr wiring.

 

[walta]

James Condon on you tube does a lot of videos on generators, he may have some videos on the avr wiring.

Look for his channel on YouTube

 

[landroverbob]

Hi thanks very much for replying I have seen many you tubes from James Condon extremely useful and well done but could not see my answer
The AVR was advertised for a harbour freight predator but extensive research found the same one also sold as as a universal Voltage Regulator fitting many different generators of 2 to 3kva - but not the honda em1900 of course. All of this type of avrs I have seen are the same wiring colors. My own workshop generator is different so I cannot pull the end off and copy the way that is wired if this fails.

Thanks for the other replies I've looked at dozens of videos all show to plug and unplug the avr none show where the wires go to before the 4 pin socket
Update
I found the original honda wiring diagram showing colors of wires and eventually found a diagram for an obscure brand of genny also with wire colors and from the two I think I can see how to go. If this works Ok I'll post some pics of it all.
thanks again for the replies
lrb

 

[landroverbob]

Pictures of results

 

[dave*99]

Nice work

 

[theoldwizard1]

Pictures of results

I am a big fan of James Condon ! You shouldn't have posted the wiring diagram. Now I am trying to figure it out !

I can decipher most of it (DCW = DC Winding, FW = Field Winding, EW = Exciter Winding) but what is VCSW (Some kind of a switch that controls MW1 and MW2 (Main Windings). What is its purpose ?)