I have the same problems as you did and I can see it was in 2006. We are now in 2007 and the voltage on the bike can drop to Zero sometimes. Could any of you nice guys out there equip me with how you finally solved your problems?? We live in Denmark and the unfortunate thing here is we can only ride 4 months out of the 12 months God has endowed us. Therefore this is kind of an emergency situation. HELP! HELP!! HELP!!!

 

If it is dropping to zero, there could be a bad connection on the regulator plug where it plugs on to the stator or even a wire on the regulator where it goes under the frame shorting out on the frame. They have been known to do that.

 

has anyone thought to check an make sure that the regulator is grounded???

there are 4-5 connections on the regulator. 2-3 from the stator(depending on 2 or 3 phase) one to the battery, and an internal ground.

The regulator has a small cast in hole on the bottom side. take a sheet metal screw 1/2" long, an internal tooth lockwasher and a wire with a connector and attach it there. run that wire to a GOOD ground and this should solve all of your problems. usually the most overlooked part of hooking up a regulator is proplerly grounding it, since the reg is painted and where it attaches to the bike is powdercoated, its usually a bad connection when they are replaced.

 

That was the best Harley tip ever!! I ran a ground wire from the voltage regulator to the groundstrap at the frame and it immediately cured a multitude of electrical problems I was having.

Many thanks to jmetro!