1996 Electra Glide Standard Charging Issue - Harley Davidson Forums: Harley Davidson Motorcycle Forum
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post #1 of 4 (permalink) Old 12-08-2012, 10:09 PM Thread Starter
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1996 Electra Glide Standard Charging Issue

Alrighty, so I am a convert from the buell side of the house, and bought myself an aging dinosaur for 6k from a very disreputable dealership, so I am not sure as to how well they cleaned it or took care of it (hell it didn't even come with a gas cap to give you an idea).

After doing a complete fluids changeout (oil had not even been changed from the dealership), plugs change, life was good for about 1,000 miles.

I was driving home one night and the lights just got dimmer and dimmer. I found that the plug from the voltage regulator to stator had come unplugged and kept coming undone, because of oil coming up into the holes and the vibrations working plug off. Cleaning, and some RTV, it was sealed on there. The voltage guage had even registered more power.

After that, the speedometer stopped working because the cable between the wheel and the speedometer had worn itself loose. Got a new one of those, and life was good for another 2,000 miles.

Then there was some kind of backpressure surge between carb and the intake manifold. Kept popping the carb/aircleaner assy right off if I closed the throttle when trying to start it. I found the rubber boot from the manifold was dry rotted, and even after replacing it with a fresh silicone one, the breather bolt grips where the aircleaner backplate attached were just not holding. So I replaced it with an Arlen Ness Stage 2.

Now I have a charging issue. A little while ago the bike wouldn't start. After a jump, I drove home, and voltage slowly dropped till the radio died and the voltage gauge bottomed out. I put the bike on a charger and had the battery tested, so all's good there. What concerns me is that now after some fiddling around under the front fairing, I've discovered the gauge was incorrectly displaying the voltage. The battery is reading 12.74v on my ohmeter with the switch off, and connecting the guage directly to it displayed the same value. The ohmeter shows after some time at a steady idle, a steady battery 12.26v

Somewhere between the battery and the gauge it loses about 2v. So after some more poking around, I've figured out that between the Battery-50A Fuse-Front Fairing Circuit Breaker it loses about 1.5v from there to the gauge it's about .2-.5 volts.

Thoughts on a component in the middle of the system that might be failing or not handling the current? Anyone run into this problem before? One problem after another with this bike is starting to become frustrating...
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post #2 of 4 (permalink) Old 12-08-2012, 10:33 PM
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First, go post an intro in the newbie area.
Second, do you have a manual?

Third, if it is starting fine, the lights are bright and at 2k rpm you read ~13V to 14V, it's just a gauge issue.

However there are 2 large connectors (6 red 12awg wires) that I hard soldered together because the connectors were an issue.
EVO Charging problems?

Harley gauges are notorious for being way off. Gas, Volts, etc...

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post #3 of 4 (permalink) Old 12-09-2012, 08:42 AM
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ya gotta a nice bike--requires a little maintenance--go with cycle electric parts--no problem
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post #4 of 4 (permalink) Old 12-09-2012, 08:58 AM
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12.26v with the engine running indicates a faulty charging system. Your meter should read higher than static volts with the engine running, about 13.5v or so.

Disclaimer : Don't believe anything I say unless you are absolutely sure that I know what I'm talking about .
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