How can i keep a voltage regulator plug on a 1992 FLSTC from slipping off?

Answer 1

I recently, yesterday, replaced the stator on my 1998 Heritage because the male regulator plug had come loose and the resultant arcing burned the insulation from the plugs, both, shorting out the alternator, burning up the regulator and the stator. I replaced the Harley stator with an ACCEL unit but found the plug did not extend thru the case sufficiently to secure the male regulator plug. I trimmed 1/16" off of the regulator plug cap to allow more plug contact, improvised a spring loaded "keeper" to secure the plug and siliconed the hell out of the external plug area hopefully securing the plug. This is a costly problem. Do not ignore the loose plug. The dealer quoted me $400 plus parts to replace the burned up stator. The stator that I used was $70 on eBay. The regulator was $70 from Truett and Osborne. The additional HD parts to do the job correctly, screws gaskets and lube, cost me another $66, so even with my labor it was still not cheap. If you will email me at sdc47us@Yahoo.com I will send you a picture of the retainer that I made. It is crude, looks like hell, but I bet it works, $2.27 at the local hardware store. I will pretty it up and refine this winter when I have the time. I understand that a commercially made plug retainer is available but I have yet to find it. The one that I purchased from a local shop did not fit the EVO. If you are the original owner ask your Harley dealer if your bike was covered by a recall for this problem, I was told that some years were, but not mine. Hope this helps. Steve