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Default 86-90 regulator-rectifier on 2003 engine?

Hello out there!

Due the fact I ve just planted an 2003 engine into a 86 frame,was wandering if its regulator can handle the extra amps of the 2003 stator output,without getting fried,a tleast until will get the right one?Something to be hooked before the rectifier?...
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Looking at the info on the Sportsterpedia:
http://sportsterpedia.com/doku.php/t...harging_system

The '86 stator only puts out 12-18v - The '03 stator puts out 19-26v - that might be too much of a difference for the regulator to handle...

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Quote:
Originally Posted by IXL2Relax View Post
Looking at the info on the Sportsterpedia:
http://sportsterpedia.com/doku.php/t...harging_system

The '86 stator only puts out 12-18v - The '03 stator puts out 19-26v - that might be too much of a difference for the regulator to handle...

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Are you sure that these are correct numbers? Two phase stator should put out around 40V AC at 2000rpm as far as I know..?
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In amps,is not too much difference;19 to 22,but extra volts can hurt,indeed.On the 86 just changed the stator & regulator last year and I ve bought another regulator as spare...so I am packed with these;but now here the dealers shot off there businesses,because de corona emergency situation...so no parts.I have to hook up a toillet paper role t0 clean up the extra volts...
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Quote:
Originally Posted by juzyHD View Post
Are you sure that these are correct numbers? Two phase stator should put out around 40V AC at 2000rpm as far as I know..?
According to the Harley documentation (The '86 stator only puts out 12-18v - The '03 stator puts out 19-26v), those are the correct numbers for 'per 1000rpm' ratings - meaning at 2000rpm, the '86 would be 'around 36volts' and the '03 around 52volts'. That should mean the '86 stator is producing around 54volts when spinning 3000rpms.

OP - Until you get the proper regulator for the engine (and I certainly would for long-term usage), if you have the spare, I would be adventurous enough to try connecting the older regulator to the '03 stator and see if it produces a regulated output in the 14.7 - 15.0 volts range. You could even feed this to a battery not connected on the bike to see if it holds the proper voltage under the load of charging a battery - Be SURE the battery is properly and securely grounded to the Regulator Ground!.

Be sure to check to see if the regulator is overheating or the voltage goes out of range after being active for awhile.

Do you have any extra lights or other loads on the bike electrical circuits?

I would expect/hopefully the regulator design to handle the extra voltage - but it IS AN UNKNOWN circumstance - Keep checking it if you try this.


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just get the proper regulator for the 2003, it fits in the same location but has higher specs for the higher output of the 5 speeds.
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Well,no extra lights,just a 55-60W bulb and a LED tail light.It seems the regulator is working fine,on the battery(AGM) I have a constant 14-14.5 volts,but if it fails-just coming to my mind-the non regulated output can burn the ignition(Daytona TT 1005)?...Maybe I have to throw on the points set up,until I get the 2003 part...As I mentioned above,we have difficulties to get parts here in Eastern Europe right now.
Thank you sir IXL2Relax,for the detailed input!
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[QUOTE=IXL2Relax;5813509]According to the Harley documentation (The '86 stator only puts out 12-18v - The '03 stator puts out 19-26v), those are the correct numbers for 'per 1000rpm' ratings - meaning at 2000rpm, the '86 would be 'around 36volts' and the '03 around 52volts'. That should mean the '86 stator is producing around 54volts when spinning

Lower voltage readings are only due to lower alternator rpm placed behind the clutch. The main problem is 19A vs 22A. I don't know what is the regulator difference but maybe later one ( part number for 03 part is 74523-94A and for 88 is 74523-84A) is specified for higher current or it just have different conector. Someone here should know that, so correct me, if I'm wrong.
I have later model stator and stock regulator on mine (bike is from year 86)and there are no problems in ten years for now. It doesn't even heat that much.

Anyway the best solution is to get a later regulator for later stator, so you'll don't have to worry!
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super duper +1 mr. juzy
all about the amperage because that is where the heat comes from.
that said, all about demand also. if the regulator is not pushed, could possible last a little while. on a pmg, a cheap 25 amp reg of a b&s would do the job at 1/3 the cost.
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Yes indeed,these 4 speed stators revolve less,and have less heat stress;with the magnets glued,they should last more than the post 90* models.Mine also in 10 year of intense use never had an issue.Well,the conector is the same.Maybe I have to hook up in parallel the spare regulator also;definetly will eat those extra amps & volts....he-he..
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