Damn I read a post like this and I loose faith in My 2006 1200C . My stator took a **** at 7,000 miles. Dealer charged $340 I think to replace. Now I see You are all experiencing repeated Stator problems at ( roughly ) 10,000 mile intervals . These are from riders who maintain there bikes not neglet them. I thought the bad stator was a Vendor issue with it being a bad wire or something. Reading here it appears to be a design . Makes Me think more about dumping this ride for something more dependable while I still have any value in it ( only $6,000 if that ) . I don't buy into the " Harley " lifestyle thing and really don't care what badge is on the side of the tank. More important to Me is reliabilty. How prevailent is the stator failure on the 04-06 1200s ? .................WVleo

 

I hear ya. But to keep the facts straight, SportyPig and I are higher mileage riders at 20K+ miles a year and our 2 stator failures have been in the 25,000-30,000 mile range. If you and Arod6 have had stator failures in the 7K mile range, that has me wondering if it's as much a function of time as it is mileage. Maybe moisture eventually getting to the windings? I really don't know, other than if I could find a quality aftermarket stator the next time, I'd sure try it. I really wish now that I had saved the last stator that smoked. I should have taken it to a rewind shop and seen if they could do anything to beef it up to make it more reliable.

The aftermarket All ***** starter sure put an end to my 12K mile starter clutch failures, but I suspect that the kick back issue affects people that live in the hotter climates much worse than northern folks because it's definitely worse in the hotter summer months.

 

Hi cHarley, I saw mine at the dealership and the wires fried right at the connection to the metal wrappings or whatever the main body of the Stator making me think it was a Vendor issue . If it is a time issue that would suck . I wonder if the upgrade for F.I. corrected the Stator issue ( different Vendor, stronger stator for FI ) ? Any 07 and up Sportsters having Stator issues ????????? Opps grandkids are up time to make the doughnuts or in this case pankakes..............WVleo

 

That's how my 2nd stator looked. Output wire was fried. I didn't see the first stator that went out, but that failure was caused by a faulty voltage regulator.

 

Check the ground connected to the back of the starter. The 06's have a problem with the becoming loose. I've logged 74,000 miles on my 06 XLC, never had any stator problems.

 

Thanks Wraith thats something to look at. SP still having voltage regulator issues. Is there a better after market one . I have the H-D Chrome one to install when I get out there, but if there is one a little stronger for the electrical system I like to try that one .......WVleo

 

I'm starting to wonder about this as well. My first Stator was replaced @ 12.1K (starter clutch @ 11.7K). Though I'm no where near the mileage of these failures the second time around, I'm very close to the ellapsed time. If this holds true; that means my starter clutch should be giving away soon, instead of the 4-5K estimate I have left on it.

WVleo - I think you and I are in the same boat. I LOVE my ride, I spent an extra 3K to get her feeling right. I love the cadence of a Harley; but being stranded in the middle of nowhere @ night waiting 2.5hours for a tow... is no fun.

 

A bad ground will give false readings for the voltage regulator. That particular ground is for the electronics on the bike. The 06 XL's seam to eat starter drives. You don't have to replace the whole starter, just the drive. As cHarley said replace the starter with an all ball unite if you can afford it.

 

Ouch! $520 @ an Indy shop - got the following items replaced -

1. Stator
2. Regulator
3. Battery

I hope it lasts more than 7k this time. If anyone finds a better aftermarket Stator, let me know.

 

and there goes the starter clutch. That's 2 failures in 20K miles. Just ordered the All ***** starter for $200 @ Eastern, per cHarley recomendation (Thanks)!

Anyone find a good aftermarket Stator yet?