Loose Voltage Regulator plug

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May 22, 2011 | 10:39 PM

D1gger

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Joined: May 2011

Posts: 684

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From: Indian Head, PA

Loose Voltage Regulator plug

First of all I wanted to say thank you for this forum and for the sticky post about electrical system diagnosis.

Tonight on a ride, my Tour Glide's voltage gauge started showing that it was no longer charging. Then my turn signals started working only intermittently. I pulled over and didn't see anything wrong, so I went straight home, hoping to make it before the battery discharged. I made it home just fine, but the gauge was still showing only 10 volts and the lights were dim.

I went on bikebandit and looked up the exploded diagram for the charging system, which showed me what the parts look like as well as how much they cost.(yikes!)

I then came in here and read the sticky on charging diagnosis. I headed into the garage with my voltmeter and went to check the regulator and stator as described in the sticky. I discovered the regulator's plug was very loose where it plugged into the jack beside the shifter pivot, and the contacts were dirty as well. I cleaned everything up, went through the diagnosis steps and tested the regulator and stator and both tested fine. So I pushed the plug back together and started the bike...

To my delight, it was charging again! so the whole problem was a loose/dirty plug. It didn't seem to have a very positive connection when I put it back together, though. I am worried that it will vibrate loose again. Is there any way to improve the retention of this plug? Or am I basically going to just have to keep an eye on my volt gauge and push the plug back together every now and then?

May 23, 2011 | 01:42 PM

O-Town D

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Joined: Nov 2010

Posts: 1,115

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From: Bay Area, NorCal

Yeah, the way the volt reg connector "plugs" into the crankcase on the older models is a Harley design that is somewhat flawed. On my old '90 FXR I used a volt reg plug retainer that looked something like a glorified paper clip; it sat down on top of the plug and was held in place by a lower crankcase bolt. Wasn't real pretty but it sure did do the job. Do a web search on it as I'm sure those retainers in various forms are still being sold by several suppliers. Good luck.
~

May 24, 2011 | 02:54 PM

D1gger

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Road Captain

Joined: May 2011

Posts: 684

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From: Indian Head, PA

Thanks for the reply and the info! I will definately be looking into that. I can probably make something up myself, I just wasn't thinking along those lines...

Jun 2, 2011 | 05:43 PM

D1gger

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Joined: May 2011

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From: Indian Head, PA

Just a little update: On the way to the dealer to pick up some parts, as well as the retainer, it vibrated loose again. I picked up the parts and headed home. When I went to install the clip, I wasn't real happy about the way it only caught the corner of the plug, so I bent the end of it into a more secure fit that holds the entire flat part of the plug firmly against the stator jack on the crankcase. It looks like it will do a much better job than duct tape! LOL!

Jun 2, 2011 | 06:00 PM

O-Town D

Road Master

Joined: Nov 2010

Posts: 1,115

Likes: 69

From: Bay Area, NorCal

"... I bent the end of it into a more secure fit that holds the entire flat part of the plug firmly against the stator jack on the crankcase. It looks like it will do a much better job than duct tape!"

Now you'll have a lot more peace of mind heading out on the road - good job! Ride safe!
~

Oct 21, 2013 | 06:46 PM

droach3

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Joined: Oct 2013

Posts: 23

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From: San Antonio

Hate to revive a long dead thread but I really gotta thank the OP on this one. The bike I am about to pick up the guy tells me.

"The only problem I have ever had is this dang little plug here (voltage regulator plug in crankcase)" Every now and then it vibrates loose or i knock it when I am washing the bike and the battery will die on you. But I have AAA so i just call them and no biggie

"

Glad to see there is a fix before I even pick up the bike! I will be fabbing up a clip the day I pick it up.

Thanks again.

Would have sent a PM if I could have figured out how

Jun 23, 2015 | 03:25 PM

thewoozel666

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Joined: May 2015

Posts: 62

Likes: 0

From: Melrose, FL

I hope you guys are still out there....will this retainer work for my 93 Dyna wide glide bike? It has a 32 amp charging system I believe and the plugs are on the outside of the crankcase...problem is that the oil filter is right in the way of the plugs preventing them from get a solid connection plus it vibrates loose...