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I replaced the stator and voltage regulator on my '04 Sporty several years ago and I'm familiar with the smell associated with a shorted stator. During the last Fatboy oil change I've noticed a similar odor (but not nearly as strong) and the primary oil was a bit dirty. Since the oil change I'd been able to detect the smell on a regular basis, but I had been monitoring the battery voltage with my PV tuner mounted on the bars and the battery was charging. I took the PV off Saturday and rode about 75 miles - no problems.
Yesterday morning I took the bike for a longer ride and on the way home the battery indicator came on. I immediately suspected a failed stator, so I made a beeline for home - fortunately I was only about 30 miles from home when the light came on. I pulled into the garage, left the bike running and verified that the system wasn't charging. Using the diagnostics guide, I was able to determine a short to ground as well as shorts between the three phases of the stator. This morning I placed an order for the Cycle Electric setup and I hope to have it within the next couple of days.
It seems as though the HD systems are prone to failure and I've experienced my fair share of issues, but this is the first time with the TC. At this point I've removed the floorboard, shifter and primary cover. So I have a few questions...
- What can I use to lock the primary / clutch in order to remove the pulley on the TC? The tools I've seen appear to be nothing more than a flat piece of stock that is fitted between the teeth - I used a brass door hinge on the Sporty.
- Once the primary chain tensioner is removed, can I get away with removing only the engine sprocket or will I have to remove the clutch basket as well?
- And finally are there any other items I should look at while I have the primary apart? I know certain model years had issues with the tensioner shoes, does this apply to a 2012 TC? Thank you for any input and suggestions.
This guy has a series of videos showing the entire job, including how to make the lock tool. I used this when I did my 06 Heritage and it was a breeze.
This guy has a series of videos showing the entire job, including how to make the lock tool. I used this when I did my 06 Heritage and it was a breeze.
So the stator showed up today and I thought I had a chance at getting this fixed tonight (I should have known better, especially the way my luck has been going lately). Went down to the garage and removed the bolt so I could take off the compensating sprocket and all the other stuff. So I'm at the point where all I should have to do is remove the rotor, replace the stator and put it all back together. Easy, right?? Not exactly - I can slide the rotor toward the end of the shaft, but it hits this raised area all around the radius of the inner primary. I was able to get everything off the main shaft without touching the clutch pack, I’m really hoping I don’t have to mess with the inner primary to get the rotor off. Anyone have any suggestions?
Last edited by gilmour68; Jul 3, 2018 at 08:17 PM.
Ended up using the dremel to grind the raised edge down flush with the edge of the inner primary like I saw on a YouTube video. I was not about to get into loosening the starter and inner primary.
Finally got the rotor to come off, Now i wonder how many of the stator screws are going to either strip or break. It was definitely burned and the rotor looks good.
Before grinding
Surprisingly, none of the screws gave me a hard time and I put in the cycle electric stator, cleaned up the rotor and reassembled the primary this afternoon. Tomorrow the voltage regulator is scheduled for delivery so I should be up and running by evening. I was surprised that the HD service manual did not mention the interference problem with the inner primary.
Last edited by gilmour68; Jul 4, 2018 at 07:36 PM.
What was your mileage when this happened. I'm approaching 50k on my Fatboy. Heard different stories about these burning up at around 50-60k. Just wondering and preparing for the worst. Excellent write up by the way.
What was your mileage when this happened. I'm approaching 50k on my Fatboy. Heard different stories about these burning up at around 50-60k. Just wondering and preparing for the worst. Excellent write up by the way.
The bike had 33500 on it when the stator went. I just got in the Cycle Electric voltage regulator and put it all back together today. Started it up and got a 14.1V reading at the battery. Took it for a ride and everything seems fine. The attached photo is of the new regulator.
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Fatboy Stator died
