Yeah I was hoping cleaning up the oily plug would solve the charging part. Since it was an intermittent problem, I didn’t take the time prove there was bad charging voltage. The one time I did test it was charging normally at 14.25 volts.

 

I made the mistake of spraying my lower with brake cleaner without reading the can first.
That stuff is amazing, but it dissolves rubber. It turned my stator plug into soft pliable paste.
Resulting in a poor connection to my VR.
I only ride short distances these days and keep the bike on a tender, so I wasn't aware that the stator wasn't charging.
Until I went out on a longer ride, stopped to enjoy the sights and couldn't restart the bike to leave.
Good thing I keep a jump pack in the swingarm bag and have all LED's for lighting. Nursed it home.
Got it started in the garage and started checking things from the battery end.

 

I probably shouldn’t have been surprised with how dirty it was when I pulled it all apart. With how messy oil changes can be sometimes. I sprayed it all down with this expensive stuff. I hear you about the brake cleaner. Some say it doesn’t damage powder coat either but I think it could.

 

What is an older bike is a funny debate
For years it was a weak point for harley. Not sure if it still is. But I also don't think it is the worse thing to replace at 17 years old. But it is not my money either.

Stator output is also the question if voltage is low. On some models it can be a PIA to get at the connections.

 

I was working on a friend of mines 2011 RK that had an intermittent charging issue but only on longer rides.. I tested everything properly and could not find a definite cause till I took the primary off to inspect the Stator.. You could see how one of the phases was black from overheating but not bad enough to cause a rise in the resistance test to each coil.. They still all measure the same..

 

My bet is that you wouldn't find a difference in resistance but a random short to ground.. I'd probably take a high-pot test to find as it's likely OK when cool.

 

What model motorcycle are you working on? Does your motorcycle have a voltage gauge? About two years ago, while out on a ride I noticed the needle on my voltage gauge intermittently jumping around. After my lunch stop, motorcycle wouldn't start. Replaced voltage regulator (Cycle Electric #CE-607) and all has been good since.

 

@Max Headflow

Not following the term "I'd probably take a high-pot test" Thanks..
EDITED: HIPOT, I found a video explaining it and apparently it's to test for the wiring used in the stator to test the integrity of the insulation.. ?? Which I would imagine breaks down as heat goes up...

 

Google AI is your friend here..

 

Sounds like the "Megger" tests we did on compressor engines ignition system back in the 80's.