Voltage Regulator/Charging Issues w/ '95 FLHTCU

[haw338]

I got the bike about 4 years ago now, and am on my 4th voltage regulator.  I don't crawl in 100 degree heat or any of that bad crap!  I like the radio cranked , and the only extra lights is on the front forks, down by the brakes.  maybe an extra 1 - 2 amps.  The voltmeter fluctuates quite a bit from 10 - 12 V, 10 when idling, around 12 with cruise on and radio up!  Am I asking for too much from my 32 Amp alternator, and is that in turn frying the regulator, or does my ground suck, or is my luck horrible!  The last time it went out it shorted out the system.   Looking for any advice, possibly looking at an upgrade in alternator, sick of going through regulators.  thanks all

[JohnS_Rosamond]

On my '88 Evo, there was a time when I went through three CCI regulators in quick succession.  Never was sure if it was the bike or faulty regulator.  I do know that after the last one was replaced (on a trip of course), I ripped all the paint off the area where the regulator grounds to the mountin bracket and I added a ground wire that attaches from the regulator mounting bolt and goes to the crank case.  I have not had regulator problems since.  Might wanna try adding a ground cable -  mine is 10 guage wire I believe.

[wulffe]

Based on John's advice on another thread I'm adding some grounds; including the regulator. Fried two regulators and one stator in the last year.
Started the regulator ground yesterday. Naturally I didn't have an appropriate ring connector or wire size and did the hardware dance (Lowes, Home Depot, Menards, then Sears - repeat in a few hours when I run into the next thing I need) so I still have to complete it.

I was thinking about running the ground to the frame bolt on the bracket that holds the regulator but when I pulled one of the bolts I discovered a rusty mess. Wonder if that might be at least part of the ground problem - even if the ground is OK to the bracket, the bracket itself might not be making ground to the frame all the time. So I am going to ground it further back and onto something I know is good - not exactly sure where yet.

[Buddy WMC]

On my '88 Evo, there was a time when I went through three CCI regulators in quick succession.  Never was sure if it was the bike or faulty regulator.  I do know that after the last one was replaced (on a trip of course), I ripped all the paint off the area where the regulator grounds to the mountin bracket and I added a ground wire that attaches from the regulator mounting bolt and goes to the crank case.  I have not had regulator problems since.  Might wanna try adding a ground cable -  mine is 10 guage wire I believe.

Did the same fix on my 93, still working like a champ.

[Old Crow]

I bought a new 32amp regulator for the shovel when I did the overhaul last year.  It came with a 4th wire in the harness.  2 to the plug, 1 to the battery and the 4th is a ground.  Tried looking back through my receipts to find out what brand, but couldn't find the receipt where I bought it.
I added several grounds to the old FLT when I put her back together, and finally the turn signals and horn will work at idle.

[haw338]

Thanks guys, just got the new one mounted today.  Did not add the ground wire yet, but so far with paint cleaned off, all is looking good.  Still going to add the ground cable though, thanks again, and I'll keep ya updated! 

[hotrodtrucks]

Hey Gang. Glad I stumbled on this thread. I have an old 85 FLHT that we have owned for about 5 years now. I have had times when I would turn on the headlight going down the road and the ol' scoot would stumble bad for a sec. Hardly ever have I had the nerve to run the road lights because it would effect the performance unless cranking the wick pretty well. Not a chance of idleing the old bike with a light on. So, ground wires are about to appear all over this ol' cowboys ride. Right after every thing that lights up is removed and mounting location is cleaned and remounted. You would think someone that has worked with big trucks and lots of hotrod cars/trucks all his life would have thought of this long before now. Oh well what can I say. Oltymerz affliction I guess. Now, with all this said. I'm wondering if the age of the lights has any effect of amp draw? I haven't changed a bulb of any kind since I've owned this bike. I have thought of converting most if not all my lights over to L.E.D. . We run these on all our auto transport trucks now. Low amp draw and last way longer. Anyone have any thoughts or feed back on that? Most would still be pretty inexpensive except the headlight. Priced those for our new trucks and they run near $275.00 each. Old bike has just turned 70K on the clock and will be going into the shop up at Bill's Cycle in Pittsburg, Kansas for an overhaul and a few upgrades the end of July. Also thinking about going to a 3 phase stator to dial up output on the amps then too. Out here in S E Kansas we have a longer riding season than alot of folks, (year round if there is no ice or snow on the road) and I do take advantage of that. Ok, enough of my ramblings. Thanks for the info. Ya'll live large, ride hard and take care. Mike.

[still_havinfun]

back in feb 1999 i install this kit in my 89 flhtcu. it is out of a 95 flhtcu-i
stator- HD FLHTCU-I #29969-95
rotor - HD #2981-95
Regulator HD # 50amp 74505-95
Reg Harness HD # 67811-95
this kit is a 40 amp
i'm pretty sure you have a larger setup than 32 amp