I have a 06 1200C with 19K miles. Recently, the engine and battery lights came on. I check the diag code and it read - low battery charge. I checked all the connections and recharged the battery.

Went on a ride today, and the lights came on again; about 20 min I noticed the speedometer lights were out, suddenly the whole electrical system shut down.

Now this puppy only has 19K - at 12K, the same thing happend, which the stealership replaced the following
1. Stator
2. Battery
3. Starter Clutch

What gives!? Does the Stator need replacing already?

The latest diag code reads - B1141

The only other thing that's happend recently is - I had to replace the rear turn signal bulb. There is a round plastic piece that holds the lead wire in place, this came off, and i couldn't replace it. So the wire is just there on its own making contact with the bulb end. I don't think this has anything to do with it, but i could be wrong.

The other thing about my ride is - when i start her up, about 75% of the time, I hear this metallic CRANK sound, that doesn't sound right. Could this be eatting up my Stator?

Getting stranded is no fun. I'm even contemplating getting a Jap crusier - even though i love my Harley.

Any thoughts, advice would be great.

 

I would get your voltage regulator checked

 

Your first problem sounds like the stator AND/OR regulator have failed. The only way to know for sure is to put a meter on them and take some measurements.

Your second issue with hearing "this metallic CRANK sound", sounds familiar if it usually happens when you are restarting a hot motor after a brief stop. This is a common problem on 1200's due to the higher compression ratio. The motor is "kicking back" against the starter much like they kicked back against a rider's leg in the kick start days. This kick back WILL eventually take out the teeth on the starter clutch gear.

What's happening with the starter, is that there is unburnt fuel left in the cylinder when you shut down the motor, and the piston has come to a stop on the beginning of a compression stroke. When you hit the ignition switch, the mixture is igniting before the starter has built up enough momentum in the motor and the piston kicks back rather than following through the stroke. There is no solution to the issue using STOCK Harley parts. The best way to put an end to this happening, is to replace the whole starter with a 1.4kw "All *****" brand starter which is more powerful that the stock starter. After replacing 2 starter clutches on my bike in less than 25,000 miles, I went with the All ***** and have not had any more issues in the last 33,000 miles. One of our forum sponsors, Eastern Performance, carries the starters and last time I checked they were around $150.00. Well worth it when you factor in the labor hours (pretty much an all day job on my bike) spent replacing the clutch gear every 12,000 miles.

 

cHarley - you are right on. At 11,700 miles my starter clutch died, the guy at the stealership said - he never saw one so chewed up. Thanks for the advise about the "All *****" - I will defienetly check it out. My question is, will there still be that "crank" sound with the "All *****" starter?

Also, the Staitor was replaced 7K ago, is it normal to have it go bad already?

 

That's pretty quick for the stator. I would bet it's the voltage regulator. As cHarley said, the only way to tell for sure is to check it with a meter.

 

If you mean the "bang" sound when the motor kicks back against the starter, I haven't heard it again since changing to the All *****. The All ***** seems to have enough torque to push through the kick back and that will prevent the damage to the starter clutch teeth.

Not from my experience. SportyPig (here on the forum) and I both have higher mileage 04-06 Sporties and we have both had 2 stator failures. All of the failures have come in the 25,000 - 30,000 mile interval range. My first stator went at 26,000 and the second at 50,600.

I have not had a regulator failure, but SportyPig lost his with his first stator failure. A bad (shorted) regulator can take out the stator, but the stators also will burn out on their own.

 

Well speak of the devil SportyPig.....

 

So it sounds like it would be a good idea to change the starter as well, as when they diag my electrical issue - since the crank case has to come off - correct?

I just spoke to the stealership - and the tech said I should replace the starter at a later date. I'm wondering if this makes sense to me.

 

The charging system, stator & regulator, can all be diagnosed/tested without opening the primary cover. Only if the stator is bad, will it necessary to remove the primary cover.

If averages hold, you probably have ~5K or so miles left on your starter clutch, so depending how many miles you ride per year, figure out what works for you. For some folks here, 5K miles is a years worth of riding.

You'll also need to allow time to order and get the All ***** starter in-hand.

 

Replacing the Stator is a MAJOR PITA. If that is the problem, shop around for a good Indy dealer. You might find a deal. I got lucky on my first Stator. Just replaced the second one myself. Like I said, it's a pain!

If it's the voltage regulator, that's a 10 minute job. Very easy.