Light Bulb keeps blowing - VR issue?

Keith S

Keith S

EHC FREE!!!!
I have had some gremlins getting started this year. I replaced my battery with a lithium battery (Battery Tender LiFe). During my first ride - after about 25 miles - the battery melted, smoldered, and I fried the switch harness on my wire plus.

I replaced the battery and switch harness. I chalked it up to the LiFe battery no liking the VR and getting over charged. I have a lot of experience with various lithium batteries and LiFe is the hardiest of the bunch. They can take a lot of abuse. While I understand Ohms Law, I am not an EE. I went back to a regular battery.

My light bulb lost the low beam. It was old so I replaced it. The next one lost the low beam. I pulled the headlight and the retaining ring had come loose. The set screw backed out so it rattled around. I figured it was just vibration and broke. This was after just a quick ride up the road and back (< 1 mile). I checked everything and was still getting 12v at the plug.

Tonight, I took a longer ride. I lost the light bulb completely at about 3 miles. I rode a little longer (about 15 miles all together) can came home. I checked the battery while it was running and got 16.3v!!!!!

My thought is that the voltage regulator is bad and over charging the battery which is blowing the bulb (and my switch harness and the LiFe battery).

Any other opinions?

Do I need to replace the stator or can I just replace the VR?

Suggestions for the VR? Up until now, the stock one has served me well.

04 Chopper DT.

Thanks in advance - Keith
 
KaptinAmerika

KaptinAmerika

Guru
Hi Keith

Yeah if you don't watch the charging system it will certainly ruin everything.
Check your stator, check from each pin to case to check for grounding, not good, and across both pins for about .1 to .2 ohms of resistance. If either test fails replace the stator also.
First and foremost do yourself a huge favor and get a battery/charging system monitor. Would have saved your lithium battery and a lot of trouble.
Then go with a quality Series VR:
CompUFire Regulator Black
CompUFire Regulator Chrome
Or do yourself a big favor and go with the 40amp 3 phase system
CompUFire 40amp 3 phase
If your having issues with blown bulbs you can go LED
LED Headlamp Direct fit to all Big Dog 5.75" Headlight Buckets
or you can go with a lower cost version which is just the bulb replacement with an LED light. I don't have those on the site yet but they will be in the next week or so.
 
Keith S

Keith S

EHC FREE!!!!
Thanks Kaptain - parts ordered. I did not get the monitor because I am not sure where I would mount the light. I went ahead and upgraded to the 40amp system. Might as well while I have it torn apart.

Greatly appreciate all of your help on this.

Keith
 
KaptinAmerika

KaptinAmerika

Guru
Take another look
I have been working towards implementing this and this just kind of kicked me in the ass.
I am modifying the system so that BD owners can easily install it to their rides and have full visual of the LED at all times.

Big Dog Charging System Monitor

Yes it is more expensive since I have to do the mods to it. But a handy person can do what I did to install it in which case you can just purchase the module by itself.

Charging System Monitor
 
Keith S

Keith S

EHC FREE!!!!
Got the parts today - thanks for the quick shipping. Bike is on the lift, but Kentucky is playing tonight...some things require my full attention!
 
Keith S

Keith S

EHC FREE!!!!
A few more questions:

I am getting 0.3ohms across the pins. Do I need to replace the stator?

The reason I ask is that I am having a heck of a time getting the stator off. I have tried the allen wrenches and it won't budge. I threaded two bolts into the holes, clamped vise grips to the bolts and pulled hard and it won't budge.

Am I missing something? Should it come off easier than that?

This is an 04. I have noticed some differences between it and the later models. To start, it was a 1 1/2" nut instead of a 33mm nut and it was a 1 1/8 instead of a 30mm nut. (it may have been 1 1/16 - I'm going off of memory).

I bought the 40amp 3 phase system, can I just bolt on the VR with my current stock stator and go from there or does it have to match the newer, bigger stator?

What alternator rotor puller works with the big dogs since I can't seem to pull it off manually.

Thanks in advance - Keith.




PS: Brew - the only thing we "pour" in Kentucky is fine bourbon.
 
KaptinAmerika

KaptinAmerika

Guru
Hi Keith

You must replace the stator with the provided unit and you cannot use only the VR.
This is a different charging system so you must use the parts provided.
I don't understand the issue your having with the stator.
Can you send me a pic to my email?
wsworx@gmail.com
 
Keith S

Keith S

EHC FREE!!!!
Sent you an e-mail with pics. The issue is with removing the rotor. I can not get it to budge. A puller is $100 so I am trying to avoid having to buy one. If I do not need to replace the stator at 0.3ohms, the 32amp VR is about the same price as the puller.
 
Keith S

Keith S

EHC FREE!!!!
Got the rotor off tonight. Spent a lot of time pulling and tugging and no happy ending. I made this rotor puller and it worked. I took a kitchen cutting board, cut it into a couple of strips, measured out the holes, drilled it and it worked. I also used some of the cutting board to make a gear stop. Which reminds me, I need to stop by Wal-Mart and pick up a new cutting board or there will be more pulling and tugging going on around here.

The rotor looks like it has a lot bigger magnets than the later models. I am trying to get the seal out now. It is kind of a pain too.
 

Attachments

KaptinAmerika

KaptinAmerika

Guru
Nice work
If you have a couple of self tapping screws then drive them into the outer edge of the seal and using your vice grips grab the screws and pull it out.
 
mastiffdave

mastiffdave

Well-Known Member
I have a monitor on mine and its mounted to where the light is visible by reflection on the rocker covers so no wires are seen. It works very well that way just saying.
 
Keith S

Keith S

EHC FREE!!!!
KaptinAmerika said:
Nice work
If you have a couple of self tapping screws then drive them into the outer edge of the seal and using your vice grips grab the screws and pull it out.
Click to expand...
So into the metal part of it not the rubber part? Would it be easier to just take off the back part of the primary case and get to it from that direction?
 
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