I installed a new stator and regulator on my 03 electra glide ultra classic been running great for about 500 miles all the sudden today check engine Iight comes on and battery runs to almost dead engine kinda struggled to stay running and heard a high pitched whine near the stator when revved above 3500 rpms. Any help would be greatly appreciated.

 

Brand of stator and volt reg? What was the code? Not sure if going the through the dash on that year gives you all the codes. Hold tripometer in, and turn on bike, release. Google code.

Did you you ride it or tow it home? Did it start? Did you put meter on battery?

Did you do the work yourself or bring in?

 

Can't think of any other option than to go back in and see what happened. Did you re-locktite everything when you put it back together and torque t the recommended value?

 

I'd check the code first. Not there, the squeel sounds like mechanical. Loose stator bolts, spun? Loose comp? If you didn't say squeel I would start by checking connections.

 

Your battery could be toast. Check the voltage at the battery with a volt meter when the bike is running, I guess jump start it. If you get 13+ volts it's charging. Then charge the battery completely and take it to have a load test performed. That is if it tales a full charge.

 

Should be around 14.4 when reved up, then you know its probably charging.

 

Holding in tripmeter won't work with 03. That all started 04. There is a way to do it but involves a jumper and counting flashes. A pia.
Pull stator to voltage regulator plug and check ohms from each stator wire to ground. Should be open. Any continuity means stator short to ground. Start bike and check stator output AC voltage. See FSM for voltage
If noise you mentioned is not normal, well you know what you gotta do.

 

I appreciate all the responses. Going to try and answer them all. After market parts I did the work myself. It just happened today was able to ride it home. I will check the voltage reg and stator tomorrow evening after work. Will pull the crankcase cover this weekend and recheck the torque on all nuts. Battery is new from July 23 have it on the trickle charger. Was getting over 14v on gauge before incident, after I came home cranked it up and was only reading 10v. Will check codes and Google. Again thanks for all the suggestions and help, much appreciated.

 

Works on my 2001. But not all codes can be pulled from dash.

 

When you installed the new Stator, were you aware of:

Service Bulletin M-1170 dated May 27, 2005... It changed the torque procedure for all 2003-2005 Touring, Softail, and Dyna models. Basically it changed the torque procedure to torque the comp nut to 75ft-lbs, then follow up with an additional 45° to 50° more turn on the nut. From the SB, "Tighten sprocket shaft nut to 75 ft-lbs (101.7 Nm) / Scribe a line (3) on the sprocket shaft nut (1). Continue the line on the sprocket cover (2) as shown. / Tighten the sprocket shaft nut an additional 45 ̊ to 50 ̊ (50 ̊ MAXIMUM)."


TT122, dated Oct 29, 2003.. It brought up the possible "stack-up" problem with the comp. When HD changed from the tapered timken to the roller on the sprocket side of the crank, the were some stackup problems. Basically, when the bearing changed it led to the comp nut being too long to provide proper clamping force to the compensator. From TT122, "Field complaints of engine noise or vibration are often traced back to a loose compensating nut in the primary drive. Use a stethoscope to isolate the source, and eliminate obvious external culprits. If it appears to be in the primary housing, first check for a loose compensating nut. / If loose, disassemble the parts and look for worn surfaces indicating poor clamp load and a diminished stack height. Replace any damaged components. When reassembling, clean the threads on both the shaft and nut, prime the threads, loctite parts with 262 threadlocker and torque to 150- 165 ft-lbs. (my note: That is the old torque spec, follow torque spec in M-1170) / If the nut seems tight there may be a stack up issue preventing it from achieving full clamp load. Try adding a 24033-70 shim under the head of the compensating nut (p/n 40392-91) and re-assemble as described above."

When you check out the primary, if the comp is loose, or it looks like damage could have been caused by a poor clamp load, it could be due to the stack-up issue, the old torque spec, or both... I would then use both the shim with the new torque procedure when putting it back together, OR you could trim the nut 0.030" at the inboard end, instead of adding a shim under the head of the nut. Trimming the nut was a preferred method on another Harley technical forum that I read..


I hope some of this info helps, if you find signs of improper clamping (comp is loose) when you check the comp/stator...


Good luck with your diagnosis and repair....