1996 Road King Battery issues
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Stage I
Joined: Aug 2024
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From: Massachusetts
1996 Road King Battery issues
I have a 1996 Road King, stock evo 80, Super E carb. I replaced the battery and voltage regulator about 2 months ago. All has been well until today. I went for a ride with a couple stops. My last stop, I shut it off, ran into the gas station, came out two minutes later and the bike was totaly dead, no lights or anything. Put a jump pack on it, got it started, let it run for 10 minutes. When I took off out of the gas station it would only buck and sputter, I couldnt accelerate. Got it up the street to my house and it died in the driveway. Not sure where to start with the issue, im not very savvy when it comes to electrical work. Any advice is greatly appreciated.
Grand HDF Member
Joined: Apr 2007
Posts: 3,725
Likes: 3,070
From: Brighton, MI
Recharge battery. See if it takes a charge. Let battery sit for a couple hours after it has been fully charged. Make a note of the battery voltage after the resting period.
Check battery connections and your grounds. If battery holds a charge, start bike and see what the voltage output is with engine running. Make a note of that voltage.
Let us know what numbers you get.
Follow this post for diagnosing your charging system:
https://www.hdforums.com/forum/evo/8...ng-system.html
Check battery connections and your grounds. If battery holds a charge, start bike and see what the voltage output is with engine running. Make a note of that voltage.
Let us know what numbers you get.
Follow this post for diagnosing your charging system:
https://www.hdforums.com/forum/evo/8...ng-system.html
Seasoned HDF Member
Joined: Mar 2010
Posts: 38,528
Likes: 6,407
From: Honah Lee
Check connections. Let us know if you have a DC volt meter
PS. Welcome to the HDFORUM. Only as a suggestion by me as a USER, make another new thread over in the newmember welcome area to say hello.
I hope you continue to enjoy your ride here with us alone with that Harley.
PS. Welcome to the HDFORUM. Only as a suggestion by me as a USER, make another new thread over in the newmember welcome area to say hello.
I hope you continue to enjoy your ride here with us alone with that Harley.
Seasoned HDF Member
Joined: Mar 2010
Posts: 21,092
Likes: 7,614
From: Poolville
Go over to the Evo section and up in the top section You'll see a sticky (thread) on electrical charging system testing.. Follow it closely and you should be able to figure it out..
Edited: https://www.hdforums.com/forum/evo/8...ng-system.html
Edited: https://www.hdforums.com/forum/evo/8...ng-system.html
Last edited by 98hotrodfatboy; Aug 5, 2024 at 07:59 PM.
Seasoned HDF Member
Joined: Feb 2007
Posts: 6,081
Likes: 1,127
From:
I have a 1996 Road King, stock evo 80, Super E carb. I replaced the battery and voltage regulator about 2 months ago. All has been well until today. I went for a ride with a couple stops. My last stop, I shut it off, ran into the gas station, came out two minutes later and the bike was totaly dead, no lights or anything. Put a jump pack on it, got it started, let it run for 10 minutes. When I took off out of the gas station it would only buck and sputter, I couldnt accelerate. Got it up the street to my house and it died in the driveway. Not sure where to start with the issue, im not very savvy when it comes to electrical work. Any advice is greatly appreciated.
2-Has voltage at battery been tested with a digital meter...at rest (bike off), while cranking and then at high idle? What are the voltage numbers?
3-Does your battery require utilization of spacers? Generally included with purchase of new battery when cables are attached on side of battery.
4-Have you checked all 4 FOUR ends of battery cables?
Seasoned HDF Member
Joined: Jan 2009
Posts: 5,149
Likes: 2,975
From: WACO
We talking about a 18 year old motorcyle. It could be almost anything. My 1996 Road King's battery went dead. Long story short. Turned out the connection between the regulator and alternator where they plug together had corroded over the years and shorted out. Had to replace regulator and stator. Test the stator. Good luck.
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Road Master
Joined: Sep 2021
Posts: 759
Likes: 936
From: Under the affluence of incahol.
^^^^^^^ This.
In particular, take apart and clean the connection where the positive large battery cable bolts on to the starter solenoid on top of the starter motor assembly.
It is the main "Jesus" connection where the ignition switch wire leading to the regulator and everything else on the bike also joins.
I had similar problems to what you describe on my 95 RK - including I replaced the regulator -- and eventually found that solenoid connection had a thin layer of corrosion over it that sort of let some current through but not enough, totally crapped out sometimes, then would come back and be ok again for a while. The connection looked ok, just a bit dull, but a clean up with Scotchbrite scourer pad fixed it right up.
The giveaway for me was that I just happened to feel that solenoid terminal was too hot to touch after a few test starts of the engine, caused by the resistance of the connection.
Its a kinda poor design where the main power supply to the ignition switch and charging circuit comes off the solenoid terminal instead of direct from the battery -- but it worked fine for 20 something years before it gave trouble so I guess its all good with a little maintenance.
I would undo and clean and retighten the battery ground cable both ends too, for good measure. Smearing dielectric silicone grease over the connections AFTER you have assembled and tightened them up helps stop it happening again. Silicone grease in that plug where the alternator stator connects to the regulator / loom is a good idea too, to keep moisture out and slow down corrosion.
In particular, take apart and clean the connection where the positive large battery cable bolts on to the starter solenoid on top of the starter motor assembly.
It is the main "Jesus" connection where the ignition switch wire leading to the regulator and everything else on the bike also joins.
I had similar problems to what you describe on my 95 RK - including I replaced the regulator -- and eventually found that solenoid connection had a thin layer of corrosion over it that sort of let some current through but not enough, totally crapped out sometimes, then would come back and be ok again for a while. The connection looked ok, just a bit dull, but a clean up with Scotchbrite scourer pad fixed it right up.
The giveaway for me was that I just happened to feel that solenoid terminal was too hot to touch after a few test starts of the engine, caused by the resistance of the connection.
Its a kinda poor design where the main power supply to the ignition switch and charging circuit comes off the solenoid terminal instead of direct from the battery -- but it worked fine for 20 something years before it gave trouble so I guess its all good with a little maintenance.
I would undo and clean and retighten the battery ground cable both ends too, for good measure. Smearing dielectric silicone grease over the connections AFTER you have assembled and tightened them up helps stop it happening again. Silicone grease in that plug where the alternator stator connects to the regulator / loom is a good idea too, to keep moisture out and slow down corrosion.
Last edited by PeterB; Aug 9, 2024 at 11:56 PM.
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