How to Replace the Voltage Regulator in a Harley-Davidson
by Gabriel Scofield
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.
Removal
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.
Installation
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.
References
Tips
- It is a good idea to perform a charging system output test after completion of this job.
Things You'll Need
- Hex head wrench set
- Standard wrench set
- Metal snips
- 6 cable straps or zip ties
Writer Bio
Gabriel Scofield started writing in 2003 for motorcycle dealership websites. He graduated from the Motorcycle Mechanics Institute with a certificate in Early & Late Model Harley-Davidson. He since has reached the level of Harley-Davidson Master Technician.
