how to troubleshoot charging system on an evo sportster

No pics, but here's a quick method of checking out your charging system...the Manual has more detailed tests, but some of them you gotta get crazy to do, so if your handy at all, this method should figure out your problem.

Ya got 4 sections to your charging system, basically...Stator, Voltage Regulator, Wiring, and Battery...

To continue, you MUST charge your battery fully, and its best to load-check it to ensure its ok....

If your static battery voltage is below 12.4-12.6 volts or better (12.8 is considered a full charge)...its either not charged enough, or its shot....

Start by checking voltage, both static and running...

Mine is at 12.8 static, and usually 14.2 running (revved up). 12.5 running right now (hence the troubleshooting)

If the running voltage is not higher than the static voltage, there is a problem...period....the regulator is SUSPECT...

If the voltage is above 14 vdc or so, your regulator is fried, and it needs to be replaced...

But wait...

Go to the stator connector located at the bottom of the frame, RH side, front....disconnect it at the rubber connector...

Connect your multimeter, set at resistance, to both leads of the stator connector (the side that goes into the primary)...if you read no resistance....the stator must be replaced...(should read .02-.04)

Check resistance from each lead to ground...if either of those reads no resistance, the stator must be replaced...(same thing, should be .02-.04)

Assuming the stator has checked out so far, start the bike and read VAC across the terminals...it should read about 18-21 volts per 1000 RPM's...

If the VAC reading is outside of these parameters significantly, the stator must be replaced...typically, it will be lower if there is a problem...

You have just troubleshooted the entire charging system, assuming all connections are clean and corrosion-free....This test is predicated on this assumption....

If you've followed these instructions, you know the problem....if you DON'T know the problem yet, you either did something wrong (volts AC, volts DC), or you have corrosion or a short you didn't find yet....

(borrowed most of this from the xl forum, figured i'd pass the info on)

checked everything out on my bike today, chased every wire, replaced a couple.. all said and done, i  need a regulator.. I'm lookin at the cycle electric ones.. good but pricey