Late 05-06 voltage regulators

[Mr. Wright]

With all the new guys buying some of these older bikes, and getting on here to see how to fix them, I thought I'd bring up an old recall, that just about bit me in the ass.
I was riding with a guy a few weeks ago, and his bike died going down the road. He pulled over and it fired right back up. A few hours later we found the battery dead. 1.2v dead.
I've had it in my shop doing other things to it, and had the battery disconnected, and charged back up. I finished up the other things, and reconnected the battery. Luckily, I was doing other things in my shop, because about half hour later, we started smelling something burning. I looked over and smoke was rolling off the voltage regulator.
Late 05-06, there was a recall on these voltage regulators, for just this reason. If you just happen to be running this stock regulator, get it changed. and anybody that is still running a circuit breaker, get it changed to a fuse. The circuit breaker will take way to long to trip before it will trip, and you will have a fire.
I happened to have a fuse on this bike, and it did blow, but not before the regulator was to hot to touch.

 

[MossBerg590]

Wasn't there a specific Date code or something to determine if it was the recalled one or not? I still don't know if mine is stock or not on my 06 Ridgeback

 

[Mr. Wright]

Someone might chime in with that info. I couldn't find the thread on it. Pull it loose, and if it says BDM on the back, change it out. Their not that much $, to be on the safe side.

 

[Mr. Wright]

This is what is on the back of this one.

 

[KaptinAmerika]

I can tell you from extensive experience that "none" of the BD VRs should be left on any Big Dog.
They were, and continue to be, a scourge to the EHC, as well as other components, both OEM and aftermarket.
Install a CompUFire or a Cycle Electric. Both are Series regulators built in the U.S and are of high quality.
While both will play with the OEM rotor and stator I highly recommend you get rid of both of those as well.

 

[Nཛ͢ཀཇཧ༏ཧי]

I can tell you from extensive experience that "none" of the BD VRs should be left on any Big Dog.
They were, and continue to be, a scourge to the EHC, as well as other components, both OEM and aftermarket.
Install a CompUFire or a Cycle Electric. Both are Series regulators built in the U.S and are of high quality.
While both will play with the OEM rotor and stator I highly recommend you get rid of both of those as well.

No link to the better parts?

 

[KaptinAmerika]

We Don't sell Cycle Electric but here are the CompUFire 32 amp models.

Chrome Billet CompUFire VR
Black Finned CompuFire VR

32 amp Chrome Billet VR Kit

32 amp Black Finned VR Kit

If your running efi you need to use the 3 phase 40amp system to make sure your getting adequate voltage for the extra crap

CompUFire 3 phase 40amp system


As a refresher, especially for the newbies, most of the 05 and newer BD inner primary cases have six little protrusions around the Rotor area in the front. This was an attempt by BD to make their system proprietary, and I imagine an effort to keep folks from putting different stators etc in that would not play right with their crappy VR, and are not required to remain. When you upgrade your system you will, if they are in place and have not been removed yet, have to knock them down a little with a file, grinder pick your tool. You will only have to do it once and then you will never have to worry about it again. The additional benefit is if your on the road and your rotor or stator go bad you will be able to get one just about any where.

Thanks for the poke
Nཛ͢ཀཇཧ༏ཧי

 

[pauly]

I can tell you from extensive experience that "none" of the BD VRs should be left on any Big Dog.
They were, and continue to be, a scourge to the EHC, as well as other components, both OEM and aftermarket.
Install a CompUFire or a Cycle Electric. Both are Series regulators built in the U.S and are of high quality.
While both will play with the OEM rotor and stator I highly recommend you get rid of both of those as well.

I agree with Curtis. My original went bad but I have noticed it straight away thanks to my voltage
display which was showing seventeen volts at idle.
Installed compufire regulator and could not be happier. It is the normal thirty two amp and it charges
the battery fourteen point one volts at idle.

Paul.

 

[francoblay1]

With all the new guys buying some of these older bikes, and getting on here to see how to fix them, I thought I'd bring up an old recall, that just about bit me in the ass.
I was riding with a guy a few weeks ago, and his bike died going down the road. He pulled over and it fired right back up. A few hours later we found the battery dead. 1.2v dead.
I've had it in my shop doing other things to it, and had the battery disconnected, and charged back up. I finished up the other things, and reconnected the battery. Luckily, I was doing other things in my shop, because about half hour later, we started smelling something burning. I looked over and smoke was rolling off the voltage regulator.
Late 05-06, there was a recall on these voltage regulators, for just this reason. If you just happen to be running this stock regulator, get it changed. and anybody that is still running a circuit breaker, get it changed to a fuse. The circuit breaker will take way to long to trip before it will trip, and you will have a fire.
I happened to have a fuse on this bike, and it did blow, but not before the regulator was to hot to touch.

Yup! I´ve been there.

 

[FrankBDPS]

Good info Shannon. I am sure the new guys will appreciate the heads up.

 

[Jwooky]

Agree with all, but I don’t think it’s necessary to replace the circuit breaker. That was a band aid. The real issue was the VR.

I also have a EFI and the 32 amp does well.

 

[woodbutcher]

thank you Shannon and Curtis for the excellent information.

 

[Ernie12]

I was going to ask about this so I'm glad it came up here. Do I have to worrying about this with my 02 Pro Sport?

 

[Jwooky]

This is a thread that I show the differences and how to replace the rotor/stator and what @KaptinAmerika was talking about has to be modified.

http://www.bigdogbiker.com/threads/charging-stator-rotor-issue.80896/

 

[FrankBDPS]

I was going to ask about this so I'm glad it came up here. Do I have to worrying about this with my 02 Pro Sport?

The only thing you may want to do to you're 02 is to get a fuse from Curtis and install it in the voltage regulator circuit. The older bikes don't have all the computer stuff on them. The only issue I have had with my charging system is the rubber plug on the case where the stator wires come out. Over the years the rubber has become mussy and oil soaked. I need to get that replaced some day.

 

[Mickeetwo]

This is what is on the back of this one.
View attachment 59192

On the bottom row of numbers, if it started with a 04 or 05 they were on the recall list. If it started with 06 or above you were supposed to be ok. I got a letter from bigdog back in Oct.07 about the recall. You could take your dog back to a dealer and they would install a circuit breaker or fuse, can't remember which one it was. I think the fuse was supposed to be the final fix. I remember some of the VR with 06 on them failed also.

 

[KaptinAmerika]

The only thing you may want to do to you're 02 is to get a fuse from Curtis and install it in the voltage regulator circuit. The older bikes don't have all the computer stuff on them. The only issue I have had with my charging system is the rubber plug on the case where the stator wires come out. Over the years the rubber has become mussy and oil soaked. I need to get that replaced some day.

Just pop a stator plug retainer on

Stator Plug Retainer

 

[Th3InfamousI]

I will say I had both VR's fail in my 04 and 07 and both times they took the Wires Plus in the 04 and the PDM unit in the 07. So therefore it was a costly repair.

In my opinion regardless of the recall, if someone owns an older Big Dog and still running the stock VR it's really time for an upgrade these bikes are all mostly over 10+ years old now. Like Curtis said its cheap, it will just save money and future headaches!

Heck, we had someone at the gathering with a VR that went out! Luckily it just wasn't charging at all and not over charging and also someone had a spare in their luggage....

Sent from my 2PS64 using Tapatalk

 

[FrankBDPS]

Just pop a stator plug retainer on

Stator Plug Retainer

CUrtis, I did that but the rubber is mush and the connectors are actually loose in the rubber and push back in when you try to make the connection. It is so bad I am afraid it is going to short out and start a fire.

 

[Mr. Wright]

CUrtis, I did that but the rubber is mush and the connectors are actually loose in the rubber and push back in when you try to make the connection. It is so bad I am afraid it is going to short out and start a fire.

The only choose you have then is to replace the VR, It is not recommended to splice those wires, and put on a new plug.
If someone can prove me wrong on that, I have a plug I'll give you.