Charging system
 

My 91 sportster stopped charging. New battery and reading only 12.7 volts when running. My question is what could it be AND WHERE IS THE ALTERNATOR. Is it the starter combined with alternator or is it somewhere else?

Thanks

It is called a "stator" and its a halo of wire coils buried very deep into your primary case.

Replacement is a BITCH. You will need a tool to hold the main gear assemblies from turning while you apply CRAZY torque to the main nut. You can use a 4" brass doorhinge for this.

You will also need at LEAST 4 foot of breaker bar and more than one 200lb man to apply enough torque to remove the main nut. That nut is set to 250ft*lbs from the factory, plus red loctite. It will NOT come off without a fight.

Once you pull all the primary gears and chain off (they usually come off as one assembly once both main nuts have been removed) you will see the stator behind them.

Here is a picture showing the stator (that halo looking thing on the left, around the main drive shaft) after you have removed the main shaft nut (and the other shaft nut) and then removed the entire primary gear set + chain as one piece:

https://www.hdforums.com/forum/attac...6-4-10-033.jpg

This is one of a handful of jobs that I would actually pay a skilled mechanic to do for me.

I agree with you on that one. I've done it on a old scrotch rocket and it's a BIAAATCH of a task. I'd rather shell out a few dollars and have a cold beer while waiting.

You're gonna want to check out my thread HERE for an idea of what needs done.

And the other guys are correct, it is work.

Do a search on these forums and check out the stator first. You'll have to have VOM meter to check out the stator. Takes about 15 minutes. Check out all your grounds and connections.

Just went thourgh this on a 01 sporty, stator checked out perfect; put on a new regulator and all good now. A lot easier to replace regulator than stator

Awesome, awesome, DIY thread thank you for posting that.