Good afternoon,

I just replaced the stator and voltage regulator on my 94 FXR Super Glide. The hardest part was pushing the bike when the ignition system used up all of the juice left in the battery. What I discovered when I pulled the voltage regulator plug, the pins were corroded and almost non-existent. The sockets in the stator plug were the same. Probably nothing wrong with either just an almost non existent connection. There is not a voltage meter / light on my bike but I did notice the lights dimming; until they went completely out.

I'm a "stock" person for the most part so I went to Big St. Charles HD, "my" Harley dealership. Zach White is my primary parts go-to for my "old" bike. They had the primary gasket, drain plug, stator, and stator bolts; had to wait for the voltage regulator. I drained the primary, loosened up the chain tensioner, and removed the drive sprocket (1-1/2" socket needed). What I discovered was that I could remove the drive sprocket without pulling the clutch. I pulled the rotor using two Allen wrenches and removed the three .021" shims (.063" total when I checked with a digital caliper). The stator bolts came out easily. One of the screws for the "alternator plug retainer" was broken. The rotor had been rubbing on the retainer and screws. The broken screw came out pretty easily. I ordered the retainer with screws online and thought I was set. I installed the stator with new screws and torqued to spec. Next the service manual indicates that the inner spacer is .095". This is .032" thicker than what was in place. Not sure why. I called my trusty "old" Harley mechanic "Captain Dave". He indicated that the thinner spacing is probably why the rotor was rubbing the retainer screws and retainer. I ordered the spacer online. Everything went together well today and I just finished a successful test ride. Note that when you bolt up the drive sprocket, check the chain deflection as close to each sprocket as you can per the manual. The manual indicates no more than .030" deflection difference between the two.. The voltage with the bike cold with the choke was 14.2 volts. At idle it was 12.79 volts (and the lights are much brighter!). Giving the bike a little throttle jumps up the voltage quickly.

I'm attaching pictures for you. Let me know if you have any questions. Thanks to all of you that take the time to share your experiences on this forum. Very helpful!

Thank you,

Chuck

Stator plug sockets corroded and almost non existent.

Voltage regulator plug pins corroded.

The start of the work with the primary cover off.

This is the .249" spacer which checked out with the service manual.

These are the three .021" thick each shims. Manual indicates .095" is correct.

Broken "alternator plug retainer" screw. Came out easily.

Insulation was stripped from one of the old stator cables.

New stator in place.

General picture. New stator in place. Note that I did not have to remove the clutch.

Old "alternator plug retainer" and the "good" screw. Note rubbing on retainer. Screw on the right is broken.

Service Manual FLT/FXR Models 1993 - 1994 Official Factory Manual page 8-35.

New voltage regulator in place. Note clutch cable clip and zip tied wrap on voltage regulator plug wires. I reused this from the original voltage regulator.

Voltage regulator plub snapped into place. I used dielectric grease on the pins.

New retainer in place. Captain Dave suggests blue Lock-Tite on the screws.

Directions with the new voltage regulator indicates that no matter how the old regulator was connected (to the copper stud) this new regulator must be connected to the silver stud. My old regultor was connected to the silver stud.

New inner stator washer at .095" inches. Thank you Homer's Cycle Shop! Found him on eBay.

Correct .095" spacer in place.

Rotor in place. I used two hex Allen wreches in the holes to guide the rotor back on. Magnets in rotor are very powerful!

.249" outer spacer.

Drive sprocket in place. Please note chain deflection up and down per service manual. I just bolted the tensioner back where it came off.

Primary gasket / primary back on. Be careful where the longer screws go! On my primary cover it was the one to the left of the drain plug, the one directly above that one, and the one closed to the top swing arm cover; in a triangle pattern.