Voltage Regulator Fried (Twice)
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Stellar HDF Member
Joined: Mar 2009
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From: Graysville, AL
Voltage Regulator Fried (Twice)
Hello, I replaced the stator and the voltage regulator on a 02 Ultra Classic. I fired the bike up, volts were showing over 14 and bike was running as it should. Twenty miles down the road I noticed the volts dropping on the gauge, a strange plastic smell and smoke coming from the regulator. Volts at the battery with the bike running are around 11.
I called the company (Amazon) and they replaced the voltage regulator with a new one. I hooked it up, double checked all my grounds and fired the bike up. Volts were back up over 14 and I thought the issue was solved. 20 miles down the road same issue volts drop, plastic smell and smoke from voltage regulator.
I'm thinking its a cheap regulator that can't handle the AC volts. I am open to any suggestions and appreciate the help. Thanks
I called the company (Amazon) and they replaced the voltage regulator with a new one. I hooked it up, double checked all my grounds and fired the bike up. Volts were back up over 14 and I thought the issue was solved. 20 miles down the road same issue volts drop, plastic smell and smoke from voltage regulator.
I'm thinking its a cheap regulator that can't handle the AC volts. I am open to any suggestions and appreciate the help. Thanks
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Joined: Dec 2012
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From: Texas
Pull the plug and check for ~26 vAC at idle and that it increases with rpm to ~50 vAC, pull the inspection plate and see if it smells burned, make sure that your battery is not dropping below ~10 vdc during the crank cycle, check all the battery cable connections for security and corrosion....and spend a few more $$ and get a MoCo regulator. If these are all good and you still have problems, starter brushes and commutator are possibly worn out.
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From: Puyallup, wa
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Try one from here, great products and a good warranty.
http://cycleelectricinc.com/
http://cycleelectricinc.com/
But the stock will work.
Stellar HDF Member
Joined: May 2015
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From: mid Michigan
Cycle electronics and get the upgrade to 3 phase. Beleave 02 still had single phase. I have about 10,000 miles on mine. You also have to get the rotor for the upgrade it is sold as a kit, all together.
Last edited by xcbullet; Jul 19, 2019 at 10:07 AM.
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I would have to agree find the short . I recently bought a regulator off Amazon thru bevel I believe. I needed one asap before a big ride last minute. My stocker started to fluctuate from 12 to 14 volts . I checked my stator for grounds and ac output. My stator checked out ok then checked my voltage regulator. And the output was 12 volts and less. So we swapped it out. The new regulators output is 14.50 volts which has been working fine in the last 5k miles.
I would check my wiring from the regulator to the battery. Mine was rubbing on the motor mount.
I would check my wiring from the regulator to the battery. Mine was rubbing on the motor mount.
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Stellar HDF Member
Joined: Mar 2009
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From: Graysville, AL
Thanks for the info guys. I will check follow your instructions on the upgrade and check for shorts. I checked and double checked the wiring on the 2nd regulator so I was surprised when it failed the same way.