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Thread: Shovelhead Stator/Alternator Replacement

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    Shovelhead Stator/Alternator Replacement

    Following on from the regulator post - I went for a 60 mile test run on Sunday. All was fine cruising 60 - 65 mph. Tested the charge after 40 miles and still showed 14 + volts. Horrible rain and wind, but I was happy to be out and popped into Lakeside Harley to pick up their last bottle of DOT 5.

    Near to home she started playing up a bit and when I got back the stator plug was toast. Inspection showed the plug had burned out and the female connectors where damaged. I guess I rushed it a bit, because last Thursday I still thought there was still a chance of getting to Wales and I reckon it is partly my fault, although it was a bit dodgy in the first place.

    I contacted Andy and he very kindly came over to the Ace on Monday with the clutch puller.

    This time round I stripped the primary in 2.5 hours, including 25 minutes to clean the threads (Loctite Purple) and line up the puller in the correct holes, one fag and one cuppa. It's much easier the second time, especially when you are not filming/photographing the process.

    No puller is required to remove the stator cover, but the magnets make it a little bit difficult.

    When I get the parts I will time the assembly for those who are interested.

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    Re: Shovelhead Stator/Alternator Replacement

    Unfortunately the plug and socket have all ways given problems which is the reason, there have been so many different types over the years. Not too sure what the best answer is to this, may-be a crimp joint and big blob of sealent. Seems a shame to bin a decent alternator for the sake of the plug.
    Sussex Coaster

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    Re: Shovelhead Stator/Alternator Replacement

    Quote Originally Posted by Simon_A View Post
    Unfortunately the plug and socket have all ways given problems which is the reason, there have been so many different types over the years. Not too sure what the best answer is to this, may-be a crimp joint and big blob of sealent. Seems a shame to bin a decent alternator for the sake of the plug.
    Thanks Simon, I've had a good look at it and decided to go with a new one. You can get new plugs, but I'll do that later and keep a spare. I've come this far so may as well go all the way with a new + spare charging system. I've cleaned up the seal, just waiting to see if it has been leaking!
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    Re: Shovelhead Stator/Alternator Replacement

    Home of the stator. Note 2 screw holes to left that hold the inner plug retainer. Mine were not tight, but had some sealant on them.

    All threads cleaned.

    Bike is now on it's side stand over night to check for leaks. Oh really!!! Yes, really!!!!


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    Last edited by El Hombre; 30-04-2019 at 05:33 PM.
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    Re: Shovelhead Stator/Alternator Replacement

    I am not a fan of the plug location and set up, have long been thinking of how I could extend the connection further up the bike and really seal off the entry point. Good luck.

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    Re: Shovelhead Stator/Alternator Replacement

    Quote Originally Posted by Paul P. View Post
    I am not a fan of the plug location and set up, have long been thinking of how I could extend the connection further up the bike and really seal off the entry point. Good luck.
    Thanks Paul
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    Re: Shovelhead Stator/Alternator Replacement

    Stator installed along with fancy chrome regulator and plug retainer. Note, the plug retainer is held by the engine mounting bolt. Hopefully it will save me some money!

    Now have to find a better route for the regulator wire to battery. It is currently under the engine and a bit doolally.

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    Re: Shovelhead Stator/Alternator Replacement

    are you trying to get it to Keslo

    john
    (old iron ass)

    BMW R80GS winter hack
    1978 FLH80 SHOVELHEAD
    1950 EL hydra glide PANHEAD

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    Re: Shovelhead Stator/Alternator Replacement

    Quote Originally Posted by devon.john View Post
    are you trying to get it to Keslo

    john
    Yes I am
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    Re: Shovelhead Stator/Alternator Replacement

    Regulator plug retainer looks good. The only ones I have ever seen before look a bit like a giant paper clip.

    I made one up by cutting up an old Shovel FX battery strap....it's held in place by your two acorn nuts on the sidestand plate there, and bent and twisted up and around the plug.

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