Charging system puts out 12.3 - 12.6 dc volts from idle to 3000 rpms. Stator puts out up to 42 ac volts.
Battery was load tested and passed. Battery will not start bike after a day of riding.
Any ideas?

 

Check for an open ground

 

No open ground, went back through the entire system.
What else should I check?

 

If you can wield a multimeter follow the checks in the link below?

https://dgcustomcycle.com/tech/diagn...ging-problems/

 

Voltage Regulator

 

Year and model of bike.
Reason: some bikes had factory problems.
For example in about 2012 there was an issue with voltage regulators on touring framed bikes.
It would test OK at lower RPM while cool and then give up the ghost as it warmed up or RPM went up.
Stranded riders.

 

You should be getting about 14.6 volts output from the regulator, not 12.6. 42 from the stator is good, regulator may be going. Check all grounds, battery cables, etc... There is a good “charging system diag” sticky in the Elect forum, follow that and see what’s going on.

 

It's a 2001 Super Glide, FXD.

 

Everything checks out except for the output to the battery.
I'm going to assume it's the voltage regulator at this point.

 

My bet is on the voltage regulator...

I went through three of them and two batteries in 6 years on a 2001 FXD chasing intermittent problems. One new voltage regulator started intermittently failing after a year and it was a **** to determine what was going on. I was talking to the local parts guy and he told me that MoCo had a bunch of intermittent voltage regulators out and I may have gotten one and they did a warranty exchange. By then, I had replaced the battery and finally determined the new MoCo batteriy was defective as well and got a warranty replacement. I was still having reoccurring starting and charging problems for over a year before I got tired of mucking around with it and replaced both the battery and voltage regulator at the same time...no problems since.