Stator plug issue?
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Cruiser
Joined: Feb 2009
Posts: 123
Likes: 0
From: E Washington
Stator plug issue?
'89 fxstc, wasn't charging so went through all the tests and all seemed to be good. After I finished the checks I noticed the end of the plug was all funky and looked like it had been hot, cleaned it up and checked the fit into the primary and it's loose, it will charge just fine as long as plug stays put pushed down tight, but a little vibration and it's not charging again. Anybody had this happen and found a good easy fix? Really don't want to start replacing parts that aren't really bad, suspect the stator end of the plug is not very nice either. Thanks for your thoughts.
Road Captain
Joined: May 2011
Posts: 684
Likes: 9
From: Indian Head, PA
I had the same issue early on when I first bought this bike. Look around for a voltage regulator plug retainer. It's a small metal arm sort of thing that bolts onto a nearby case bolt and holds the plug tight together. Then clean up the contacts really well, use some dielectric grease when putting it back together and put that retainer on nice and snug. Should only be a couple bucks...
Stellar HDF Member
Joined: Apr 2009
Posts: 3,039
Likes: 11
From: Northern Ontario
I had the same issue early on when I first bought this bike. Look around for a voltage regulator plug retainer. It's a small metal arm sort of thing that bolts onto a nearby case bolt and holds the plug tight together. Then clean up the contacts really well, use some dielectric grease when putting it back together and put that retainer on nice and snug. Should only be a couple bucks...
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,196
Likes: 3,086
From: NW AR
My bike came with the retainer from the factory.
You might try bending the prongs a little so it all fits in tighter. You might need to splice a new connector onto your regulator. I don't know if they are sold by themselves, but you could use one cut off a dead regulator.
You might try bending the prongs a little so it all fits in tighter. You might need to splice a new connector onto your regulator. I don't know if they are sold by themselves, but you could use one cut off a dead regulator.
Tourer
Joined: Aug 2006
Posts: 282
Likes: 7
From: Southern MD
My guess is you have a 22 amp system. Mine did the same thing and I fooled with it constantly. The fix is a 32 amp setup. The pins are much larger. You can even get stators that have wires instead of plugs. I soldered my own wires directly into the stator pins.so there is nothing to get loose now.
Here is an example: http://www.jpcycles.com/product/381-596
Here is an example: http://www.jpcycles.com/product/381-596
Grand HDF Member
Joined: Apr 2007
Posts: 3,724
Likes: 3,065
From: Brighton, MI
Common problem with the plug and another common problem is the plug starts to wick/leak primary oil.
I had same problem and cleaned the prongs (on plug that is on the block), carefully spread them out a little further so the each prong is a little fatter for better bite, and I also trimmed some of the rubber off (again on the plug located on the engine). My prongs were recessed a little, so I trimmed the rubber with a razor to be flush with the prongs (actually the prongs are a hair proud of the rubber now).
I also cleaned the inside female sockets in the regulator plug, tightened them up a hair with needle nose pliers and reconnect. Was a much more solid connection and tighter feeling. I know the terminals are making better contact now. Then I installed (homemade) the metal plug tab prevent it from coming off thingy. That was about 3 months ago and all is good so far.
However, I think this is an early warning sign that the rubber is starting to degrade and get soft (common) and a new stator is inevitable just because of that damn plug! Just hope I can make it till winter down time. YD
I had same problem and cleaned the prongs (on plug that is on the block), carefully spread them out a little further so the each prong is a little fatter for better bite, and I also trimmed some of the rubber off (again on the plug located on the engine). My prongs were recessed a little, so I trimmed the rubber with a razor to be flush with the prongs (actually the prongs are a hair proud of the rubber now).
I also cleaned the inside female sockets in the regulator plug, tightened them up a hair with needle nose pliers and reconnect. Was a much more solid connection and tighter feeling. I know the terminals are making better contact now. Then I installed (homemade) the metal plug tab prevent it from coming off thingy. That was about 3 months ago and all is good so far.
However, I think this is an early warning sign that the rubber is starting to degrade and get soft (common) and a new stator is inevitable just because of that damn plug! Just hope I can make it till winter down time. YD
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Ultimate HDF Member
Joined: May 2006
Posts: 6,590
Likes: 444
From: Ohio
Worst case scenario: Because the connection has been loose, there can be arcing there that will harden the rubber on the stator end and degrade the metal parts of the plug. No fix besides new parts. That keeper is your friend, if you don't have one, get one.
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Thread Starter
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Cruiser
Joined: Feb 2009
Posts: 123
Likes: 0
From: E Washington
Thanks guy's, I'm trying Yankee dogs fix to see if it will work for now. Shortening the rubber helped a bunch and got the sockets out where I could see them and also lets the plug with the pins go on a lot further and it feels much tighter and actually feels like it snaps on now. Home made retainer has the paint drying as we speak. Thanks
Elite HDF Member
Joined: Oct 2005
Posts: 3,872
Likes: 83
From: Canton, Michigan
Common problem with the plug and another common problem is the plug starts to wick/leak primary oil.
I had same problem and cleaned the prongs (on plug that is on the block), carefully spread them out a little further so the each prong is a little fatter for better bite, and I also trimmed some of the rubber off (again on the plug located on the engine). My prongs were recessed a little, so I trimmed the rubber with a razor to be flush with the prongs (actually the prongs are a hair proud of the rubber now).
I also cleaned the inside female sockets in the regulator plug, tightened them up a hair with needle nose pliers and reconnect. Was a much more solid connection and tighter feeling. I know the terminals are making better contact now. Then I installed (homemade) the metal plug tab prevent it from coming off thingy. That was about 3 months ago and all is good so far.
However, I think this is an early warning sign that the rubber is starting to degrade and get soft (common) and a new stator is inevitable just because of that damn plug! Just hope I can make it till winter down time. YD
I had same problem and cleaned the prongs (on plug that is on the block), carefully spread them out a little further so the each prong is a little fatter for better bite, and I also trimmed some of the rubber off (again on the plug located on the engine). My prongs were recessed a little, so I trimmed the rubber with a razor to be flush with the prongs (actually the prongs are a hair proud of the rubber now).
I also cleaned the inside female sockets in the regulator plug, tightened them up a hair with needle nose pliers and reconnect. Was a much more solid connection and tighter feeling. I know the terminals are making better contact now. Then I installed (homemade) the metal plug tab prevent it from coming off thingy. That was about 3 months ago and all is good so far.
However, I think this is an early warning sign that the rubber is starting to degrade and get soft (common) and a new stator is inevitable just because of that damn plug! Just hope I can make it till winter down time. YD
I can only add that I took a small pick and held the stator terminals in position so I could push the regulator plug firmly until I felt the 'click'.
Prior to doing this, I would get two years out of a battery. Since this fix (in 2006), I am seven years with the same battery. And still strong.
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