Do you know that your DU-5 is not generating current or is it just that the cut-out is shot?
I'm not sure if its possible to still get solid state cut outs (Gene Harper or Antonio Esteves). But I understood in the past that if your generator is still capable of putting out curent, and you remove the bad cut-out, you can adjust the third brush to try to match the current draw of your lamps or shoot for a little less to protect your battery and solder in a Motorola MR1121 rectifier/diode for one-way current. It will the just keep on charging. I got that far, reducing output of a DU's to 3 amps for a headlingt and tail light. and installing the MR1121 but never installed the modifierd generator to try it. I thought I had better install a little digital voltmeter somewhere on the bike to monitor the battery against overcharging if I did.
To test and adjust DU generators I made a plate that bolts to the lathe to which a generator mount was attached. I then ran the generator from a pulley on a shaft in the chuck using the cross feed to adjust belt tension. The generator was wired in a circuit including a battery, ammeter, and several bulb sockets to adjust load. I could then alter the generator output by moving its third brush to match a selction of bulbs.
Frankly I'm a total ammateur at such things but it seemed to be working. That was ong ago. I still have three DU-5 I did this to.
