Hello, Tritonthrasher.
Thanks for the suggestion. I tried it this afternoon, spinning the shaft at various speeds up to 3000 rpm.
More speed does indeed give me more volts, I measured 13 volts at 3000 and a current of 7amps. However, unless I ride permanently in second gear I'll never charge the battery. Lucas recon that max output should be available at 12-1500rpm, and the cutout should pull in at a little over 1000.
I think the unit is shot!!!
raindodger.