Was out riding last weekend and battery and check engine light was coming on intermittently. Once I pulled it apart I found the 3 hole stator plug was very oily. Bench tested regulator and it passed all the bias tests. Stator passed the three tests. Test rode and light came back on so regulator seemed to fail only when hot. Installed new regulator and am out test riding today. So far no light. Thinking that oily plug might have contributed to it going bad. Used silicone as a temporary fix to try and keep the plug dry. If you have an older bike you may want to look at that connection. Number 4 in pic.

 

doubt that makes a diff. if you used a vom, you basically did a go/ nogo test and still can have stator issues. all it takes is a few good strands to pass a test and yet have a stator with low output. an area of concern is the stupid stuff hd used to seal the pigtail to the stator wire, this can fail and if you use an oil with high enough sulfur common with ep additives, it will attack the copper and dissolve it, been there done that and it past all test quite awhile til it got bad enough that the vom caught it.

 

Older bikes don't have that connector.

 

When I got back from ride that day, battery voltage was down to 12.49. Been out riding several times since new regulator and now it’s been close to 13. Debating whether to replace stator since it’s 17 years old.

 

I’d consider my 2009 an older bike. Guessing if you have a regulator that looks like that picture it has same connection.

 

@Rocking_it

Could you explain how you tested the voltage regulator?

 

IMO, that aint that old. Stuff before 2006 did not have that connection..

 

Did tests like in this video.

 

If you're going to try and fix it you'll have to remove everything and get at the backside of the stator plug inside the primary.
The oil you see is primary fluid, and is seeping through where the wires pass though the plug.
At that point just replace the stator for piece of mind.

 

FWIW. that test only does a basic check if the rectifier inside the regulator. It does not check the voltage regulation of regulator itself or the function of the diodes at a higher reverse voltage (PIV).