How to Replace the Voltage Regulator in a Harley-Davidson

by Gabriel Scofield
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A motorcycle charging system is made up by three main components, the alternator, voltage regulator and the battery. The alternator consists of two main components: the rotor which is mounted on the crankshaft, and the stator, which is fastened to the crankcase. The voltage regulator is a series regulator with shunt control. The circuit combines the functions of rectifying and regulating. The voltage regulator is not repairable; it must be replaced if it fails.


Step 1

Unplug the regulator from the alternator lead; this is beneath the regulator.

Step 2

Cut the six cable straps and bend back the two metal tabs securing the regulator wire to the frame member.

Step 3

Remove the battery, battery tray and the seat. Disconnect the regulator wire lead from the main circuit breaker. Remove the remove regulator mounting hardware and the regulator.


Step 1

Position the regulator at the frame down tubes. Install the mounting hardware.

Step 2

Route the wire lead along the inside of the bottom frame member; connect it to the main circuit breaker.

Step 3

Secure the wire to the frame with six cable straps (or zip ties) and two metal frame tabs.

Step 4

Install the seat, battery and battery tray.

Step 5

Plug the regulator into the alternator lead.

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