Question about 2005 Harley Davidson XL 1200 C Sportster Custom

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Battery not staying charged

How do i change alternator on 1200 xl custom

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The sportster does not have an alternator, it has a stator. Are you sure it is the stator? First check the stator and see if it is putting out any voltage, to do this you disconnect it from the regulator on the right front down tube at the bottom. Use a multimeter to read the voltage, I forget what the values are but they should climb with increased RPM. If you find the stator is the problem get a manuel, it is a pretty big job and I can't go thro all the steps here. You do have to remove the primary cover and clutch basket, the stator is attached to for wont of a better word the fly wheel. The suggestion that I can make that is not in the manuel is to attach a pull wire to the stator wire before you remove it to make pulling the new wire easier,

Posted on Mar 04, 2009


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Engine and battery light come and stay on. I have a 2006 1200 custom. what could be the problem, it runs fine but the lights are dim and speedo light did go off

Hi Hdmoto77, perform the following tests:
1. Fill acid type batteries to proper levels.
2. Charge battery overnight at 1-2 amps you need 12.5 volts or better after charging.
3. Hook up battery positive cable, then with your multimeter on the milliamp scale connect one lead to the negative battery post and the other lead to the ground cable. Meter should read 3 milliamps or less, 10 milliamps with a radio, 15 milliamps with radio and CB. If your meter reads higher you need to isolate the circuit by pulling fuses and circuit breakers one at a time and observe meter for drop in aprerage then get out your test light and track down the short in that circuit.
3. Make sure all connections are clean and tight especially the negative cable at both ends.
4. Hook up volt meter to battery and start engine, if meter falls below 9.5 v while cranking replace battery.
5. With engine running at 3600 RPM battery should read 14.3-14.7 volts if not continue tests.
6. Unplug voltage regulator from alternator at crankcase by front of primary cover.
7. To test voltage regulator go to:
8. With ohm meter, one lead grounded, touch alternator pin meter should read infinity, if not replace stator.
9. With ohm meter, both leads touching alternator pins meter should read 0.1 to 0.2 ohms on 1989 and later models. 0.2 to 0.4 ohms 1988 and earlier models, if not replace stator.
10. With volt meter set on AC scale, both leads touching alternator pins meter should read
16 to 20 volts AC for every 1000 RPM'S 1989 and later and 19 to 26 volts AC for every 1000 RPMS. If not replace rotor.
17. For a free wiring diagram please visit the website below and good luck.
Harley Davidson Wiring Diagrams and Schematics

Aug 29, 2011 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

2006 xl 1200 0nly getting 13volts dc at battery new regulator and battery my stator is putting out 20 volts ac at idle reved is 100 volts ac is that to much or normal ?

Make sure that your battery is fully charged when taking doing these test and the bike should not be at idle RPM, it should be at about 2000 RPM or a little better. You should be reading at least 25 volts AC out of the alternator and between 14.5 and 15.0 volts DC across a fully charged battery. If it's getting 13 volts at idle, it will probably come up a bit when you increase the engine RPM. It might take a minute or two for the voltage across the battery to peak out. If it doesn't, check the ground on the regulator, it must be grounded correctly. I usually put a star type lock washer between the regulator and the frame on both mounting bolts to ensure a good ground.

Good Luck

Apr 10, 2011 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

Storing 2006 HD 1200 XL Custom for the winter. I have it hooked up to battery tender. Periodically I will take it off the tender when indicator light turns green, indicating battery is fully charged. ...

yes, the charge will bleed off just a bit in two or three days, just enough to reset the battery tender. it shouldn't take but a few minutes before the battery is again "topped off" and the green light comes on. But keep in mind that even with a battery tender, age will eventually get to your battery and it'll go bad. The battery tender extends the life of a battery but it can't extend it forever.

Good Luck

Jan 29, 2011 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

Battery charged, Start button does nothing, Turn Signals Flash

It does sound like your alarm is still on. try manually turning off the alarm. Please post theresults. Hope this helps.


Nov 09, 2009 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

I am trying to find out where the charging system cable that connects to the battery goes???????

The charging system is in basically two parts. The alternator is in the primary case. The output from the alternator is alternating current so it much go into a rectifier/voltage regulator. The regulator has a plug and a large gauge wire coming from it. The plug connects to the mating plug from the alternator. The large gauge wire can go to either of several places depending on the model of your bike and the country of destination. It can go directly to the positive post of the battery, to the post where the large battery cable connects to the starter, or to the main circuit breaker. Regardless of where the large black wire from the voltage regulator connects, it's basically a direct connection to the positive post of the battery.

Nov 03, 2009 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

I have charged my battery overnight and i still need to bump start my bike most of the time when riding and using the head light it stays bright so i dont think that it is the alternator

has the battery been tested, bike batteries last maybe 2 years, charge it up and have it tested, any Kragen can do it for free. doubt the problem is the alternator.

Sep 15, 2009 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

Just changed battery now want start how do you reset the alarm?on

r ur battery cables secure-is batt charged-wat about the starter motor that mite be bad or the wirin to-if itz turning r u gettin fuel to the carbs

Aug 20, 2009 | 2006 Harley Davidson XL 1200 C Sportster...

2 Answers

Bikes dead!! Battery wont charge, been charging all night Help!

You didn't mention if you charged the battery in- or out of the bike. If H-D has a modern alternator, it may have failed diodes that are draining the battery and stealing charge current if charged while connected. If the battery was made in China . . . oh, well.

Jul 01, 2009 | 2006 Harley Davidson XL 1200 C Sportster...

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