So pretty much dead battery again today. This is the 2nd time I have found my connector for the stator on the front of the primary disconnected. I did adjust my clutch yesterday which means I had to loosen the adjusters on the cable which runs through the same area. But I do not recall ever even coming close to the connector. The fit of the connector leaves much to be desired. I cannot feel it snap into place or anything like that. So short of replacing the stator and the rectifier side connector. Has anyone else with these old EVO's had this issue and resolved it easily and cheaply?

I am thinking of using some black gasket material that does no solidify, or even some silicone to help bond them together.

We went on a pretty good cruise yesterday, must have been running on the battery the whole time. I was just happy to be on the road, I did not notice the volt gauge when riding. When trying to start it today gauge said it only had 10v on it when I was trying to start it. I noticed it was turning over a bit slow and it just wouldn't fire. I was like wtf? Then I noticed the gauge, so the 1st thing I checked was that damn connector since it has happened once before. Sure enough, it was just laying there. Uggh!

 

http://www.ebay.com/itm/HARLEY-STAIN...aafd03&vxp=mtr

 

Most likely what has happened is the rubber on the stator plug has deteriorated and the metal terminals inside are now moving. Not uncommon. Really bad design by The MoCo.

Cheap and Easy Fix:

X-acto knife, small 'dental' style picks, carb cleaner (or other spray cleaner), and some fine needle nose pliers.

Shave a bit off the connector that passes through the inner primary.
Douche the connector with the cleaner. Clean the regulator plug too.
Use the picks, stick it through the stator plug rubber to get under the metal terminal connector and push up a bit.
Use the pliers to pull the metal termnals up (not too much) and then 'snug' them a bit to make the connection tighter. They are just a split tube that has spread apart.
Take the regulator plug and while you still have the picks poked through the rubber on the stator end, snap the male ends into the female stator.
You should faintly hear the click and also feel it.
Done.

It won't do any good installing the part Beemer posted, unless you're getting a good connection. Once that is done, you can put one of those on. I didn't, and have had no problems.

I did this back in 2006. I had never gone more than 2 years on a battery before then. The last (HD) battery lasted 8.5 years, and I only replaced it (Big Crank) because it was sounding a bit tired when the temperature was below 50 degrees.

 

Thanks both of you! I can certainly get a better connection on them. Think I have a good idea of what you explained. I work in the electronics field, so I think I can handle it, LOL. Just knowing they are somewhat serviceable is good to hear. And might as well have the piece of mind and put that retainer on as well after I get a good connection. Much appreciated.

 

My bike came with a retainer from the factory. Attaches to one of the engine case bolts.

 

So I did order the retainer, and finally had a chance to install it last night. That procedure left much to be desired. Why the hell would MoCo build it so they had to run a bolt through the case and then nut it on the other side? Poor design, as there is just barely enough room to get a wrench on it.

I had a scare when I was first trying to loosen it. When wrenching on it, it was super tight and turning slowly. I kept thinking I am going to bust this damn bolt, and then it gave way with a snap. Thought to myself, there it went dammit. But nope I just must have finally broke free all the corrosion, then I found the nut on the other side. Finally got it out and installed the retainer. See pic. No more chance of accidentally knocking connector loose again. Thanks guys, I woud have never even known about that thing if it wasn't for you. Thanks (Beemervet) fort the link!

 

Good you got it fixed.

On the shovel I had issues with the plug coming loose, so I fixed it so it wouldn't come out anymore. I opened up the primary and removed the stator and removed the rubber boot around the wiring completely. Removed the plugs on both the stator and the rectifier and used waterproof connectors with some extra wire to run thru the case, then sealed it with silicone to close it up. Stator dis-connects outside of the case and the wires tuck up under the rectifier out of the way. No leaks and it never comes unplugged.

The newer dresser type setups are much better, but this works well with those pesky small plugs and pin setups.

Griz

 

No problem bud, that's what we do here.

 

I did exactly the above two seasons ago and working great ever since. I do have a new stator ready to go just in case. I also made my own stator plug hold down thingy as the ones I seen on ebay looked flimsy. Mine is made out or 1/8 inch steel stock and painted wrinkle black to match the engine. Good luck! YD

 

May look flimsy but its not. It's stainless steel, pretty sturdy. Great piece of mind. But yes if you have the means to make one that looks good, I'm all for that too given you have the time.