Question about 2003 Harley Davidson FXD Dyna Super Glide

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Replacing stator. I know the battery and voltage regulator ok

Do you have any more detail on removing the clutch,primary chain,adjuster, and compensating sprocket so I can replace the stator. I know they must be removed as a single unit. I have the outer cover off. not sure how to take the balance of the items off with out taking something apart I don't need to.

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  • Harley Davidson Master
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This job requires a manuel. You can either buy one for about $40.00 or check one out at your local library. Not only will it give step by step instructions on disassembly but it will give all of the proper torq's for reassembly.

Posted on Jul 25, 2009

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1 Answer

I have a 1999 softtail how do i change the stator


Drain the primary fluid. Remove the outer primary cover. The stator is behind the compensating sprocket in the front of the inner primary. Increase the slack in the clutch cable at the adjuster. Lock the primary drive with the locking tool (may be purchased from Harley or Drag Specialties if you don't have one). Unbolt the primary chain adjuster from the inner primary. Remove the comp nut and nut holding the clutch basket on the trans mainshaft (this nut has right hand threads).Remove the primary drive as an assembly.Remove the rotor. It is held on magnetically. Unplug the voltage regulator from the stator. Remove the 4 bolts holding the stator to the engine case, and throw them away. You will need new stator bolts to install the new stator. Do not reuse the old ones. Remove the stator. Installation is the reverse of removal. Some models also require the removal of the inner primary in order to remove the stator. If this is required, replace all the seals in the inner primary while you have it off. A service manual will be a great help if you do this job yourself. Torque specs are rather high for reinstalling the primary drive, so you may want to consider having a shop do the job. Good luck!

Dec 07, 2012 | 2003 Harley Davidson FXD Dyna Super Glide

1 Answer

How do you change a 2002 Harley Road King stator?


Disconnect the battery. Drain the primary and remove the outer primay cover. Take the engine sprocket nut off, take the clutch adjuster out of the center of the clutch assembly and remove the mainshaft nut. This nut has LEFT HANDED THREADS. Remove the nut that holds the primary chain adjuster. Take the engine sprocket, clutch assembly, and primary chain off all together. Then, pull the rotor off the engine sprocket. It can be difficult to get off due to the strong magnets in it. Once off, there are four small bolts holding the stator on and two small screws holding the plug into the case. Installation is the reverse of disassembly. Torque the small Torx bolts that hold the stator on to 40 inch pounds. The engine sprocket nut torques to 150-165 foot pounds with one line of Loctite 271 heavy hold thread locker in it. The LEFT HANDED threaded mainshaft nut torques to 60-80 foot pounds with a single line of Loctite in it. You'll need a primary locking bar to keep the engine from turning while applying torque to the engine sprocket nut and the mainshaft nut.

Good Luck
Steve

Aug 15, 2011 | Harley Davidson FLHRC Road King Classic...

1 Answer

How do i replace the regulator & stator on a 92


There's nothing to replacing the regulator. It simply bolts to the frame. The wires from the regulator to the stator plug into the plug on the lower left front of the engine case. The larger longer wires runs back along the frame and up to the positive post of the battery.

There's a bit more to replacing the stator. To replace the stator, disconnect the battery and drain the primary case. Remove the outer primary cover. You'll have to take the engine compensator sprocket nut off and remove the mainshaft nut that holds the clutch assembly on. To get the clutch assembly off, remove the snap ring in the center of the clutch assembly and remove the clutch adjuster. The mainshaft nut is inside the hole in the center of the clutch assembly. The nut has LEFT HANDED THREADS. Take the nut off the primary chain adjuster and take the engine sprocket, primary chain with adjuster, and the clutch assembly off all together. The rotor is on the engine sprocket shaft. It can be difficult to get off because of the magnets inside of it. The rotor has two holes in it. I use two long bolts and put them just into the holes deep enough to hold the rotor by squeezing the ends together. Pull the rotor off. The stator is held on by four small Torx bolts and it has a wire support that is held on by two small sheet metal screws. When you install the new stator, make sure you use thread locker on the threads and torque the bolts to 40 inch pounds of torque. The sprocket shaft nut torques to 150-165 foot pounds of torque. The clutch mainshaft nut (LEFT HANDED THREADS) torques to 60-80 foot pounds. You'll probably need a locking bar or some way to prevent the engine from turning while you torque the nuts.

Good Luck
Steve

Aug 01, 2011 | Harley Davidson FXR Super Glide...

1 Answer

MY REGULATOR/RECTERFIRE BURNT UP. IM LOOKING TO REPLACE THE WHOLE SYSTEM.WHAT AM I UP AGAINST WHEN I TAKE THE PRIMARY COVER OFF?


You'll have to take the compensator sprocket nut off and the clutch assembly off along with the primary chain. The compensator nut is quite large and on very tight, 150 Foot Pounds fo torque. To get the clutch off, remove the snap ring and take the clutch adjuster plate out. There is a nut in the hole that has LEFT HANDED THREADS. Take this nut off and the nut on the primary chain adjuster. Then. take the engine sprocket, clutch assembly, and primary chain off all at once. You'll have to pull the rotor off to get to the stator of the alternator. This can be difficult due to the strong magnets in it. I use two long bolts and insert them in the holes on the rotor. Squeeze the ends together and pull the rotor off. There is a special tool for this but it's not necessary.

Good Luck
Steve

Jun 25, 2011 | 2004 Harley Davidson FXD - FXDI Dyna Super...

1 Answer

How do ichange my altanator


To change the stator in your alternator, you must first disconnect the battery. Then drain the primary and remove the cover. Take the compensator nut off the sprocket shaft and remove the nut on the primary chain adjuster. Then, remove the circlip that holds the clutch adjuster into the center of the clutch assembly. Remove the mainshaft nut that holds the clutch assembly on. This nut has left-handed threads. Grab the compensator sprocket and the clutch assembly and remove these and the primary chain all at the same time. Behind the sprocket shaft extension is a shim or several shims, remove these and remember where the go. You'll see the rotor. It has two holes in it. Use some long bolts that will go into the holes. Insert the bolts and squeeze them together. Pull the rotor off. It may be difficult to get off as it has very strong magnets in it but it will come off. Behind the rotor is the stator. Remove the four Torx bolts and the two small screws that hold the plug into the case. Remove the stator. Replace the stator and all the rest of the assembly is the reverse of the disassembly. The mainshaft nut (left-handed threads) torques to 60-80 foot pounds. The compensator sprocket nut torques to 150-165 foot pounds. You'll need a locking bar to prevent the engine from turning while applying torque to these nuts. Adjust the primary chain to have 3/4 to 7/8 inch up and down play with the engine cold. Replace the primary cover and add oil. If you are going to attempt to do this job, I'd strongly suggest you purchase a service manual.

Good Luck
Steve

May 24, 2011 | 2003 Harley Davidson FXST Softail Standard

3 Answers

I have a 1992 haritage that is not charging how do i solve my problem? is there an altinator or ? if so how do i pull it off any help please


Step 1. First things first, load test the battery. Most places like Auto Zone will do it for free. Even if it measures over 12.5 vdc it can still be bad under a load. Battery is typically rated at 19 amp hours and 270 Cold Cranking Amps (CCA).

Start the engine and measure DC Volts across the battery terminals, the regulator should be putting out 14.3 - 14.7 vdc at 3600 rpm and 75 degrees F.


Step 2. To check the regulator unplug it from the stator. Take a test light and clip it to the negative terminal of the battery and then touch first one pin and then the other on the plug that goes to the regulator. If you get even the slightest amount of light from the test light the regulator is toast.

To do this with a meter which is more accurate: black lead to battery ground, red lead to each pin on the plug, start with the voltage scale higher than 12vdc and move voltage scale down in steps for each pin. Any voltage is a bad regulator.
You may get battery voltage on all three pins on the newer 3 phase regulators.
The no voltage is for older type regulators with diode indicating the diode is bad and the regulator needs replacing.


Step 3. On the other part of the disconnected regulator plug. Set the multimeter for Ohms x1 scale and measure for resistance across the pins of the stator. You should read something around 0.1 to 0.2 ohms for the TC88 32 amp system.


Step 4. Then check for continuity between each pin on the plug and frame/engine ground. The meter needle should not move (infinite resistance)(digitals will show infinite resistance) if the meter needle does move (indicating continuity)(digitals will show some resistance), recheck very carefully. If the meter still shows continuity to ground the stator is shorted (bad).


Step 5. Set the meter to read A/C volts higher than 30 volts (the scale setting for voltage should always be higher than the highest voltage you expect or you may fry the meter). Start the bike, and measure from one pin to the other on the plug (DO NOT cross the multimeter probes! - touch them to each other). You should read roughly 16-20 vac per 1,000 rpm.


Step 6. If the battery was good under load test, if the stator is NOT shorted to ground, and the stator is putting out A/C voltage, then the regulator is bad (most likely even if if passed step 2)

May 23, 2011 | 2000 Harley Davidson FLHTCUI Electra Glide...

1 Answer

How do you install a stster on a 2002 harley davidson electraglide


The stater is connected to the crankshaft on the left side of the engine
Drain primary oil
Remove outer primary cover
Remove clutch ,clutch hub (puller needed)
clutch hub is reverse thread
remove compensating sprocket on crank.
remove chain adjusting rubbing block
pay att. to position as if at the end of adjustment you may want to replace chain
remove chain with hub/sprocket
remove rotor
unplug wires from stator
remove stater.
you will need a clutch hub puller
check chain for wear replace if needed
check rubbing block for wear

Now Really Get a manual !!
find one here under other

http://www.repairmanualclub.com/motomanuals/index.php

Feb 08, 2011 | 2002 Harley Davidson FLHT Electra Glide...

1 Answer

Want to no what all has to come out to change trans 2003 deuce


To change the transmission you will have to disconnect the battery then remove the outer primary cover, starter, clutch, primary chain tensioner, stator, (clutch, stator and primary chain come out as a set) inner primary cover, exhaust, clutch cable and then transmission. Sounds like a big job but if you are mechanically inclined, have the tools and have a weekend to yourself it is reasonably easy.

Nov 19, 2009 | 2003 Harley Davidson FXSTDI Softail Deuce

1 Answer

Change a stator


First secure the bike on a lift. disconnect battery.remove standard footpeg.Remove standard shifter. Remove all allen head bolts from outer primary cover. Some bolts are longer so keep track of where they go.Two bolts on the primary inspection cover also hold the outer to the inner primary case, so remove the cover.Now remove the outer primary case.The clutch,primary chain,adjuster, and compensating sprocket must be reoved as a single unit.Once you have done this take a rag and grasp the rotor and slide it off of the main engine shaft.Unplug the stator and remove the set screws holding it in place.Reverse procedure to install new stator.

Nov 20, 2008 | 2003 Harley Davidson FXD Dyna Super Glide

1 Answer

Change a stator


First secure the bike on a lift. disconnect battery.remove standard footpeg.Remove standard shifter. Remove all allen head bolts from outer primary cover. Some bolts are longer so keep track of where they go.Two bolts on the primary inspection cover also hold the outer to the inner primary case, so remove the cover.Now remove the outer primary case.The clutch,primary chain,adjuster, and compensating sprocket must be reoved as a single unit.Once you have done this take a rag and grasp the rotor and slide it off of the main engine shaft.Unplug the stator and remove the set screws holding it in place.Reverse procedure to install new stator.

Nov 10, 2008 | Harley Davidson FXDI Dyna Super Glide...

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