A few years back I was going through my 02 Dyna battery cables and found the ground cable from batt to frame, the frame terminal end had two wire strands intact in the terminal end. check those terminals real good. Also check the positive ends. Check the wire from the reg. up to the 30A circuit breaker (copper stud) behind the fuse panel. Check those connections and might as well replace that CB while you are in there.

 

Well after Checking the Stator under "a Load" with it plugged into the regulator, while not running, I scraped a bit of insulation form both the stator wires, and started it up to check the A/C output voltage with it plugged up, idling it was only 10VAC, revved up alot it only went up to 11VAC. So under "a load" it is bad and cannot put out enough to keep the battery charged. So off to get a new Stator this evening after work and install that, that has to fix it now with a new Voltage regulator and will have a new stator also.
Thanks for everyone's help

 

@JC1966

Please let us know the results
Have a good 1

WP

 

You using an RMS volt meter?

 

Here you go FWIW

Depending on the regulator the DVM will read about 15 volts for shunt and about 38 for series regulator..

 

BTW, Another issue that can occur is that the center of the rotor can brake out or the crank nut can come loose keeping the rotor from spinning.

 

Well over the weekend I got the new stator installed, but it seems someone that had the bike b4 me ( I've had it since about 2015 or so) installed one of the "Hayden M6" automatic primary chain tensioners, that uses 2 springs, an inner spring and an larger diameter spring wrapped around the inner spring with shims on the bottom. Well the larger outer spring is broke in 3 pieces. DAMN, so I guess I may just go back with the old original Manual chain tensioner, since I cannot find just the springs anywhere, you have to buy the whole damn complete kit just to get parts. 1 place overseas "W&W cycles" has just the spring for €28.91 + shipping which now-a-days, the shipping will prolly be more than the whole dang set of springs. and who knows how long it takes to get them here, plus I've seen videos of those things, they look like at high speeds that chain is so floppy, so I dunno about that thing. Plus I heard a few ppl say the springs do break alot. My bike only has 33,000 original miles for a 99 model. I have no ideal when that Hayden was put in, but I know I have had it for 11 yrs so who knows how long the spring has been broken. so its still not ridable yet. So I have not tested the charging system yet without the chain tensioner put back in and the cover buckled up. Hopefully that that solves the charging issue. Will keep everyone informed once its all buckled back up.

 

IIRC, you can go direct to Hayden to get the parts..

 

Tried, their website is down, So I sent them an E-mail to see about that

 

When you first put in the new battery, did you fully charge it before riding , or go for a 30 min+ ride to charge it?

If you put a note full battery, I'd imagine a 8 mile ride won't be enough to fully charge it.