[Hogdog]

Any Electrical Engineers out there???

Bike: 89 Ultra

The voltmeter at speeds above about 600 RPM reads 13 volts with lights on and 14 volts with lights off. No Problem, Right.. When I put the brake on, the voltmeter drops below 12 volts (i mean way below like 9-10 volts). When I take the brake off voltmeter stays low but moves back to 13v when I goose her. The turn signal when engaged causes the voltmeter to dip below 12 volts at signal frequency . Is this normal or is this a sign of a regulator problem??? I have a lot of trouble with the battery going dead after a long park, but when I disconnect battery hot lead the battery will hold its charge. Could these problems be related?

[mwelych]

Sounds like a short somewhere... Not sure if its the charging system. Have you got a manual??? I certainly don't have the skills yet to tackle something like that. I'm sure someone else can jump on that one...

[chucktx]

you are charging, but not at the correct amp/volts. it also sounds like you have a bit of a drain on the battery. i would suspect the reg. there is a test you can do, it is outlined in the manual......kinda long to post.

[Hogdog]

Thanks guys for the help. Yes I have a service manual but not a HD-35500 or Load Tester. I have been chasing this problem forever. In the past I have taken her to the dealer ship and they say everthing is OK . Guess the only way to fix this is to buy a 35 amp meter and load tester. Isn't the regulator suppose to kick the alternator to output more current when the load is increased?? Is the volt meter on the bike suppose to dip when the turn signal is on, is this normal for HD design?? Before i spend $ on test equipment I would like to know if this is working as designed. Since the Stator test uses cheap instruments I have checked it and appears ok. Also, the bike has a couple after market lights on the forks but thats the extent of non-stock juicers.

[Hogdog]

Mwelych, in regards to increasing skills, this forum is the best for that. I have learned so much from the BB, I am so close to giving the finger to the local dealership!!! Yeehaw There are some pretty savvy guys you watch this forum, like chucktx.

[Tiny86]

Hotdog
I ride an 86 EVO mine has done the same thing for the last 15 years I have been through the entire charging system twice and It still does the same thing A feller once told me to upgrade to a 33 Amp charging System and that will cure it. I havent done it, it still works if it aint broke dont fix it I plug the Bat tender in if im gonna leave her in the gee-rodge for a while. charger upgrades ive seen are a couple hundred bucks and the Manual tells how to install hope this helps

Tiny

[chucktx]

load testers from harbor freight are pretty inexpensive....i am not sure what the hd35500 is. the amp gauge will show a slight decrease as power is pulled through it....lights, sigs, ect. just a slight wiggle. the regulator is supposed to control the alt. amp flow to the battery. the battery volt/amp tells the volt reg how much to charge. make sure all connections are clean. make sure the reg is grounded. keep us posted on the progress....

[Slimjim]

I'd also give the battery a good checkup. Could be a bad cell. Check the battery voltage when you hit the starter. Shouldn't drop below 9-10 volts. If it drops to 8 or less, I'd suspect the battery.

[cowboy]

hotdog how long have you had this bike ? & how long do you let it set ? my brother has a 89 ultra & has let it set for a month & hit's the starter & vroom it's alive , if you have to jump start it after it set for a few days you have a open curcit some where , could be just a swtch worn out or a crecked wire double check the conecters on the extra lights up front , also double check the Ing swtch it self it might be just dirty or worn out from time

[Hogdog]

Hey, thanks to all who have contributed some great ideas, she goes up on the lift this weekend to check these suggestion outs. As my buddy in Calif once said "I'll be back" with an update. This is definitely going to be a learning experience. A previous starter problem was fixed by cleaning the 1,000 harness connectors, I think I will start on the wires.

Slimjim, I have replaced so many batteries in her, I had to buy a battery company, lol I'm pretty sure the battery is ok, at least the last time I checked.

Cowboy, I have suspected this to be the root of many of her problems, so I think an electrical system rework (rewire, new switches, connectors etc) is in order

Lets Ride!!!!!

[skull2007]

i'v always heard the stator and regulator should always be replaced as a unit, thats it's a bad idea to do only one without doing the other

[mwelych]

I've heard that too...

[VYBR8ER]

Check all of your ground connections, especially the main wire from the battery to the engine. Make sure the cable hasn't deteriorated which can be seen by the green/white powder between the crimped on lug and the individual wire strands. Also make sure there is a star washer under the lug and wherever it bolts to. Check the ground going to you voltage regulator and the negative terminal of the battery. You shouldn't get much more than 1 ohm resistance, I prefer .5 ohms or less. I would also take out every light bulb and make sure there is no corrosion inside the light sockets. When you put the bulbs back in use some dielectric grease to keep the contacts clean. All of your symtoms look like a grounding issue.

[Hogdog]

Hmmmm, Thanks for the reminder about the stator/regulator replacement, I have heard that also, Stator replacement looks beyond me. Checking all ground points sounds like a great idea, looks like a good place to start. Thanks again for everyone who has offered suggestions

[chucktx]

stator replacement......piece of cake. if ya need to do it all it takes is the manual and a bit of time!!

[Hogdog]

AW right, Chucktx, clear the way and let me at er!!!

Thanks,

[hotroadking]

Replacing the stator is a lot of work but nothing difficult

If you have the tools you can do it.

Get the SM and follow the steps


You need a breaker bar,get a metal bar about 3 ft long from Lowes or Home Despot, I got a piece in the gas pipe section, works great.

You'll need I believe a 1 1/8 inch socket, try an ace hardware they usually have that especially in the locations that are close to farm areas, farmers work on a lot of stuff.

Parts
Stator
Might need Rotor, check magnets etc, plan on it
Qt of primary oil
Primary gasket
Inspection plate gasket
Derby cover gasket
Red locktite
Locking tool for primary chain

[chucktx]

the socket i needed on my 06 was 1 1/2......89 may be 1 1/8....

[hotroadking]

Ya might be right, I'd have to check when I get home at work I'ts what I can recal.

[chucktx]

either way, it is an easy job....takes time, but easy. socket size can be determened as soon as the outer primary is removed.....have fun and keep us posted!!