Question about 2002 Harley Davidson FLHTCUI Electra Glide Ultra Classic

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2002 FLHTCUI Electra Glide Ultra Classic: What's approx. cost for a stator / regulator repla...

What's approx. Cost for a stator / regulator replacement on this model bike.? Davde C.

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HD = Hundred Dollars, voltage regulator.
Stator replacement = big dollars because labor intensive. The part is around $100, maybe more by now


Posted on May 17, 2010


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How can I increase the resistance?

in majority of cases a bad stator will be indicated by failing following test:
Check resistance from any one pin to the engine ground terminal - this should not read any indication - maximum resistance or open-circuit.
If you read 'short' in that last test, then your stator is bad.
(if open, it is not quite guaranteed your stator is good however - but in majority of cases a failed stator will fail this isolation test)

Check the AC voltage outputfrom the stator with engine running:
Leave stator disconnected from the R/R and start the engines.
With meter set to read AC Volts check
All three should be the same value - any significant difference of one reading will indicate a bad phase and the stator is probably defective.
At idle this should be ~ 20V* and rise to ~ 70V* at 5K rpm.
I hesitate to use absolute numbers here as this can be different between models and test equipment and especially the engine rpm!
What you are looking for is same value between phases and like increase on each phase as rpm increases.
If any of the above tests raises suspicion, pull the cover & inspect the stator. It is simple to do and can set your mind at ease by seeing what it looks like. Hopefully NOT with 1/3 of it a black charred mess!

If you have to replace the stator and R/R, especially because of a shorted R/R and excess current drain, be especially careful to ensure that your wiring has not been compromised. Replace any cable &/or connector plug that is not in optimum condition.

Now on to the alternative R/R replacement

Preface:When this thread first written, there really wasn't a good Series Regulatorwidely available as a replacement candidate. Now there are a couple of options that are in play.
This thread is read by many non-Triumph owners so I will define the replacement strategy into two groups

1: If your bike marque/model generally has a robust stator with low failure rate amongst the population, then MOSFET Regulator remains a good reliability improvement for high-failure SCR Shunt Regulators.

2. If your bike marque/model suffers from a relatively high failure rate in the general population, then MOSFET Regulator will do NOTHING to improve this situation and selection of a Series* style Regulator becomes a much better choice.

* The short version is that a Series Regulatorwill run much lower current in the stator and so it will have the stator itself producing lower dissipated power, run cooler and be more reliable.
Generally, a much better device regarding the reliability of the stator. The only downside - until recently - has been cost vs good value MOSFET Shunt units. However that 'value' is achieved if stator replacement does not have to be added to the equation!

Mar 27, 2016 | Motorcycles

2 Answers

Test dyna regulator

NEVER EVER pull the positive cable... thats an old trick for cars and old style charging systems... but then again it's your harley not mine. you need a DVOM set to AC volts to test the stator and set to DC volts to test the regulator... anwhere from 5-20 ac volts coming out of stator and 12 volts dc going TO regulator... yes then regulator, no AC volts out of stator... pull the side cover as mentioned above...

Dec 28, 2013 | Motorcycles

1 Answer

I have a peugeot xp6 runnin fine but doesnt charge the battery whats wrong

If not charging then it can only be either the stator windings or the regulator/rectifier. The silver "box" with fins on it is your rectifier. Good chance that's the problem...Try another rectifier and put a multimeter on battery terminals. Check voltage when not running then check with bike running. Fully charged battery should show approx 12.4 volts. With bike running it should show approx 13 plus volts which will tell you that it's charging. Usually it will be the rectifier rather than the stator windings that stops it charging.

Dec 14, 2012 | 2008 Peugeot XP6 Enduro 50

1 Answer

I have a 1996 f3.. we replaced the voltage regulator last year and got a new battery at the same time. this year i take it out and things are good for the first 800 miles i rode. now i can charge the...

look for 3 wires coming from the stator to the regulator, the same color, these should be the 3 phases of the stator and any pair of these should put out maybee 50v AC, with the bike running.
Also each pair of these should have similar resistance(engine stopped)and none grounded to earth
Then put the volt meter across the battery, it should read somwhere around 14 v DC with the engine running.

No AC -stator problem
Yes AC, No DC- regulator problem
Voltages can vary between makes and models, but hopefully this is the simple explanation

Jun 19, 2011 | 1996 Honda CBR 600 F(3)T

1 Answer

Hello,I replace the Stator and battery,on my 86,cavalcade 1400 LXE...starter ok,but the wires gets over hot with the voltage regulator together...thank you!

The wires from the Stator to the Regulator/rectifier do get very hot. Remember that the stator always puts out maximum power and the reg/rect shunts what ever your bike does not use to ground. A very wasteful thing to do, but that is what Suzuki decided to do with most of their models. There is a yahoo email group for these bikes joined through a link at - try it.

Aug 26, 2010 | 1986 Suzuki GV 1400 Cavalcade LX

1 Answer

Faulty regulator rectifier- can't start the bike

I have a '07 C90T.
I have just replaced my stator. I replaced the reg/rectifier earlier this year. I replaced the battery one year ago in October.

I firmly believe what started the problem. Two guys that I told I didn't need help, but they pressured me to let them help. They hooked a battery backwards to my bike. A lot of people believe that's what shortened the life of the rectifier and stator.

But keep this in mind. The connections for the regulator/rectifier are not waterproof. I had done a lot of rainy riding and I first found a burnt connector on the discharge side of the reg/rect. My mechanic told me I needed to replace the reg/rect so I did but I soldered the wires and made them waterproof. I didn't do this on the stator side of the reg/rect and a few months later, when the bike quit charging again, I found that connector burnt, so I cut it out and soldered and waterproofed it.

Two days after we got back from a 700 mile round trip to Red River, NM, my bike quit charging again. This time though, I have a voltage meter on the bike, so I was aware of the problem before the bike could strand me someplace. Get one of those btw.
When I checked the old stator after I replaced it, I found the stator good but the pulse signal generator bad. It's required that you replace both btw. You have to, they are joined at the grommet.

Ok well, the battery cost $60 last year and I replaced it myself.
The reg/rect cost $140 through my mechanic and I replaced it myself.
Got the stator online for $173 shipped and they advertise a better stator that puts out 20% more power.
Not counting little things like solder, tape, heatshrink and such, I'm out a little less than $375 on my charging system.
I hope it's a done deal.
Again, some think the problems began when the battery was hooked up wrong, but I lean to believe the sub-standard Suzuki connections may have a hand in this.
Hope this helps. . . Joe

Jun 18, 2009 | 2007 Suzuki Boulevard

1 Answer

'07 Sportster 883 Altenator problem

Your sportster does not have an altenator, it has a stator and a voltage regulator. What I would do is LOAD test the battery first. Next I would check my stator. To do this there is a plug on the bottom of the right front down tube, on the lead coming from the stator use a muti meter to measure the voltage with the bike running of course. I forget the exact values but as you rev the engine the voltage should climb. If it dosen't you have a bad stator, if it does the voltage regulator is bad. Pray its the voltage regulator, they cost about the same for the part but is much easier to replace.

May 02, 2009 | 2003 Harley Davidson XLH Sportster 883...

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