My stator was putting out figures as per manual - 19-26VAC/1000RPM. Resistance was good, too. But there was only 12.8V on the battery. Stator shorted to ground. Insulation was cracked on two wires going from stator coils to the plug in primary housing. It did not touch the primary or any other metal parts. I think there was a shortage going via primary oil.

Look at the pic here:
https://picasaweb.google.com/JoseJal...11067401168866

 

Yeah, thats exactly what I suspect. What the heck, I was going to replace the regulator anyways. Now I only need a stator.

 

Mine did the same thing as NutterFLHs did. Both wires to the plug wore thru. I bought mine last summer from Zanottis HD. I want to say it was around $79 for a 32 amp.

 

LMAO , sprayed my coffee all over my laptop screen. Good one Hess

 

Sorry, Lynn (and Baron). I sometimes get a get grumpy at night.

 

noooooooooooooooo

 

Hello again my fellow Evo'ers. I just wanted to give you guys an update. Turns out I am not just an idiot, but I am a retard. I didn't miss diagnose my bike once, I screwed up twice. The shop called, they found the problem. My stator is fine and my charging system is working perfect. He suspects I didn't even need the regulator. He checked everything and its all putting out just as its supposed to, but as I mentioned, the battery is not getting a charge. Turns out there is some sort of a relay between the regulator and the battery. Apparently that has failed. He did a hot wire test and hooked the regulator line straight to the battery and the system worked perfect. Passed the load test and was 13.8-14.2 during all conditions. My mistakes were as follows.

1. I was correct in thinking the stator was fine when it was 20ish volts at idle and 30ish reving up.

2. The regulator was probably OK and I wasted the money on a new one since its doing the exact same thing as the old one did. The fact it was recently replaced (as shown by the splice) should have been a clue to me it wasn't that old.

3. My biggest mistake. I checked voltage at the regulator output wire with the bike running. It was only between 1.5 and 1.75 or so volts. Hence my mistake. My thinking told me that that was not correct and I should be getting full battery voltage (13-14 volts). Turns out that is all a regulator THAT IS NOT HOOKED TO THE BATTERY is supposed to put out!!!!!!!!!!!! WTF!!!!!!!!!

4. As was explained to me, the power from the regulator was simply not getting to the battery as the relay was toast and was not allowing power to get to the battery and was just dumping current to nowhere. We checked that wire with a meter and it ready battery power but the mechanic said that doesn't mean the relay isn't shot. Bypassing it proves it is.

So, I screwed up by installing a regulator I didn't need, and never fixed what should have been a simple repair. The mechanic suggested I just hard wire the regulator permanently to the battery, but I told him to do it the factory way. So he'll get a relay Monday and I'll have my bike back in no time. What a freakin' pain in the *** as well as a good learning lesson. This is why in the future I intend to leave electrical issues to the experts. They are just NOT my bag. Bottom line, stator fine, regulator fine, relay shot. F-ME!

End of story............... I hope.

 

And that darn relay is oh so cheap to buy too. That older evo's didn't even have a relay between the regulator and battery.

 

Yep, thats exactly what he said. Said I don't even need the POS. Maybe I should call him back and just hard wire it.

 

mine wired straight to the 30amp breaker. im thinking mine is not original as well.