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I have a 96 Springer softail, last year the original stator failed due to one of the stator plug wires frying. I put a new stator in and in one year now this one tests bad, no voltage coming off the pins. Is there something else I should be looking at as a cause? Can a faulty regulator cause a stator to fail? Man I really don't want to keep replacing stators. Thanks for any help.
There are very limited number of reasons a stator fails. Either it shorts out or it opens. It is just a coil of wire with magnets rotating around it. If your stator is failed, you should be able to determine why. If the plug is damaged or fried, that would be an indication that excessive current was being drawn from it. Same thing with an open. Shorts usually happen for physical reasons like vibration or rubbing etc.
If you are burning them out, causing them to open, you should look at how much load you put on it. For example, radios, lights, extra markers, hi wattage head light. Being that you mention it is a springer softail there is not a lot of room for all the extra electrical components but it should still be a consideration.
To your question, can the regulator be the cause? It could be, if it is failing and creates an excessive current draw, it could cause the damage you mentioned. Since the regulator was mentioned as having been changed, I would change it at the same time you do the stator (cheap insurance).
How old is the battery? Is it the same battery as last time? Though unlikely, your battery could be creating a hi current draw as well. If it has been a couple years, you might want to consider changing it as well.
So if you put a new stator in and change the regulator and replace the battery, your entire charging system will be new and should not have this happen again (assuming you don't have 1200 marker lights and glow sticks on the bike).
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