Alternator and Regulator Question
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Road Captain
Joined: Jan 2011
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From: Pineville, LA
Alternator and Regulator Question
The motor I bought for my present build came out of a 1996 Electra Glide. It only has 18k miles and is in mint condition. My question centers on the charging system. The motor has the high output rotor and stator on it and they are pretty much flawless so I am not planning on replacing them. My question is the regulator. I am assuming I need to get a high output regulator (74505-97A) instead of the normal one (74519-88A) so I don't fry it. The bike has a Thunder Heart harness so no stock wiring. In the service manual, it shows the connection from the regulator to the circuit breaker to be on the ignition switch side which means the system is not protected by the breaker from the regulator output. I am planning on putting the regulator connection on the same side of the breaker as the connection to the starter. Any issues with that? Any other things I should be concerned about with the high output system? The last bike I built had a regular output system so I wanted to check in case I am missing something silly.
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From: Cental, MI
If it will Plug in...I do Not think it will give Problems.. But, remember, the Voltage Regulator on the older Harley (2-Wire) system, simply shunts excess "charge" to Ground... the Alternator outputting 100% all the time...and the Regulator Taking the "heat"..Literally.. High Output??? I don't use 'em...but, I do Not use much 12v at all..But, If You can use it.. so be it..
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Road Captain
Joined: Jan 2011
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From: Pineville, LA
If it will Plug in...I do Not think it will give Problems.. But, remember, the Voltage Regulator on the older Harley (2-Wire) system, simply shunts excess "charge" to Ground... the Alternator outputting 100% all the time...and the Regulator Taking the "heat"..Literally.. High Output??? I don't use 'em...but, I do Not use much 12v at all..But, If You can use it.. so be it..
HDF Community Team
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From: NC USA
Starter has small wire to actuate the solenoid, leave it alone.. One large cable from the battery to the starter, one that goes from where the battery connects to starter, that goes to the main breaker. Regulator output connects there on the AUX side, same as ignition, lights, etc.
Shovels connect on the BAT side of main breaker. Evos connect on AUX side of main breaker. Evo uses 50amp for main. Copper is BAT and silver post is AUX
Shovels connect on the BAT side of main breaker. Evos connect on AUX side of main breaker. Evo uses 50amp for main. Copper is BAT and silver post is AUX
Seasoned HDF Member
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From: South Carolina
Starter has small wire to actuate the solenoid, leave it alone.. One large cable from the battery to the starter, one that goes from where the battery connects to starter, that goes to the main breaker. Regulator output connects there on the AUX side, same as ignition, lights, etc.
Shovels connect on the BAT side of main breaker. Evos connect on AUX side of main breaker. Evo uses 50amp for main. Copper is BAT and silver post is AUX
Shovels connect on the BAT side of main breaker. Evos connect on AUX side of main breaker. Evo uses 50amp for main. Copper is BAT and silver post is AUX
I think Cycle Electric instructions say to connect the regulator output to the output side of the main breaker (silver stud) on all models.
Last edited by Dan89FLSTC; Feb 26, 2026 at 01:33 PM.
Club Member
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From: Beyond Fucital
It doesn't matter what side you connect it to, the starter, stator and VR are not overload protected.
My 94 EVO's connected to the battery side of the 30 amp breaker.
My 94 EVO's connected to the battery side of the 30 amp breaker.
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Road Captain
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HDF Community Team
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From: NC USA
In the mid to late 80`s the factory couldn`t make up its mind where to connect the regulator output, some were on the battery side of the main, some were on the output side.
I think Cycle Electric instructions say to connect the regulator output to the output side of the main breaker (silver stud) on all models.
I think Cycle Electric instructions say to connect the regulator output to the output side of the main breaker (silver stud) on all models.
Last edited by t150vej; Feb 26, 2026 at 02:40 PM.
Thread Starter
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Road Captain
Joined: Jan 2011
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From: Pineville, LA
It doesn't matter to what I am building (non-touring), but according to my 1996-1997 FSM and the factory parts book for the same year and 1999, all softails came with a 30a breaker. But, I have noticed quite a few places the books don't agree, so who knows. Again, thanks for the help guys. Y'all are great.