1993 fxsts charging problem. I ran through the sticky on testing the system. I have a new regulater and getting 23v ac at 1000rpm but not getting voltage to the battery. If I wiggle the plug around I can sometimes get it to charge. So I think it is the plug coming thru the case.

Any other ideas other than pulling the primary to put a new plug in or hard wiring. Thanks for any ideas

 

I hard wire my EVO.

 

If you get 23VAC all the time at the plug socket, it's probably the regulator plug. Try distorting the pins some when you push it in. Make sure it is seated completely. Try one of the spring hold down things if your bike didn't come with one.

 

I took and Xacto knife, a small pick, and a pair of needle nose pliers to mine. I was going through batteries every two years before I got the damn connection to 'snap' like it was supposed to.

 

I was thinking of doing what Hackd did, it doesn't seem like it is snapping into place. I spread the regulator plus a bit but seems a little worse now.

 

The Xacto was used to trim a bit off the end of the stator plug. I used the small dental type pick to extract and hold the terminals in the stator plug while I snapped in the regulator. I also needed to 'tighten up' the terminals a bit with the needle nose pliers.

Been 10 years since that Hack Fix. Last battery went 8 years. I only replaced it because it was sounding a tad weak cranking the bike, with temps in the 30's.

 

Take Hackd's advice, it works. Here's a link to my thread about this issue last year. After Hackd procedure and adding a retainer you won't have to think about it again. Until you pass it on to the next guy that is.

https://www.hdforums.com/forum/evo-c...tor-issue.html

 

Care to share what you did to hard wire it? My cycle electric stator/plug is leaking a little only after second season of use. Tired of dealing with it. Cleaning it up and forcing silicone in there did not last too long. YD

 

Uncle G's flowable silicone fix didn't work for you???

 

Lasted about 300 miles. Ready to just dig into the primary, still trying to decide if I pull stator, clean and degrease rubber plug, slather silicone and reinstall, or remove rubber plug, cut and splice wires, and fill with silicone/right stuff.

But definitely going to open primary and pull clutch/chain/comp to get at the plug do it right and take my time. I picked up 12 ga oil resistant wire, adhesive lined heat shrink, right stuff gasket maker/sealer, silicone sealant, and water proof connectors.YD