Just tried installing a new voltage regulator. Got all the way to the point of removing the nut that connects the regulator to the main circuit.

When I started to loosen the nut, the entire screw came out. And it appears to be stripped. Had to saw the screw in half to get the cables loose.

Now, question is, can I use another screw to replace the part that broke? Or do I have a major problem? There appears to be another screw with a nut on it on the other side of the plate.

Help, I am at a loss.

 

Jonmerrill, You neglected to state which year bike you have. If it's an 06 or earlier, the regulator output lead connects to a 30 amp breaker. Replace this breaker. They're cheap.

The breaker has 2 connection post on it; one colored silver, and one colored gold. The regulator connects to the silver post. Also connected to the silver post is a lead going to the switch on the console.

 

It's an 05. I just went out and looked, after being depressed most of the afternoon, and see that it is a breaker. Does it just pull out? Thanks so much for your answer. I can now sleep tonight.

 

I've had to explain the charging system so many times that I built a display in my shop. Attached Photo.

You are correct. The breaker snaps into a bracket located on the front side of your rear tire splash guard. From the breaker's Gold colored terminal is a wire which connects to the starter and makes contact with the battery's positive cable. Disconnect your battery before changing the breaker.

These breakers are not water proof and can often fail due to corrosion. I always recommend replacing them every few years.