alternator, stator, voltage regulator ( Y1302-02A8 )

[DeTe]

Hello,
Classic issue I guess - stator and voltage
regulator in my Ully 2006 got fried.
I rewinded wire (made sure it goes the same
rounds and length), and bought a new regulator
(HD part Y1302.02A8 ), and re-assembled gear.
I tested grounded stator and its resistance (OK),
and alternator output, also fine (tests described
in service factory manual). The point is,
that brand new regulator gives only 2V output.
I wonder whether I smashed it with my ignorance,
or there was something changed between 2006 and 2009
in ulyssess, so brand new (2010) regulator does
not work? Is it something with alternator and
regulator with 2008+ series, or I just broke it?
Shall I buy a new alternator too ? Mount bracket
for the new regulator I bought matches, the only
difference with new regulator was different type
of connector regulator => battery. As the connector
pair was attached in the box, I replaced battery
cable ending with attached connector.

Actually, is there a way to test regulator without a
bike?I mean to find out whether it is broken or not,
without connecting it to the motorcycle ?

My guess is that I must broke the new regulator somehow,
but I just want to make sure there wasn't something
changed with alternator/regulator, which makes brand
new not working..

?

PS. I bet there's no difference between 1,2,3 alternator
output wires in the connector, as far as all three are
connected with three input wires of the regulator?

http://dtpw.pl/buell

[Rays]

Y1302.028 is the upgraded 3-phase regulator that suits the pre-2008 XB's. The later XB's 2008>, have a single phase stator so the regulator is different.

If the stator output is the correct AC level as you say then you should be OK, the wiring of the three phases to the input of the regulator does not matter - any order will work.

You said you replaced the '77 connector to match the new type regulator connector but the output of the regulator is only 2 volts (DC). How did you determine that? The regulator MUST be connected to the battery to test it is charging. If you left it disconnected and measured across the DC output you will not get a valid reading.

I also assume that you were really, really careful about what was positive and what was negative when you fitted the new connector? You would normally find out the hard way if you got it wrong because the 30Amp battery fuse would have gone up up in smoke - the case of the regulator is corrected to the negative output.

The correct way to test the output is measure across the battery terminals with the engine running (regulator connected) and you should measure 13.5 Volts DC or so if the regulator is charging.

[DeTe]

Hello, thanks for clarifying some points for me!
Regarding positive and negative on regulator output, I measured with tester - it blinks (-) diode or (+) diode, depending how I connect tester probes ( tester has two probles - red and black, so I noted which diode blinks when I connect it to battery, and determined which regulator needle order has the same diode blinking. Anyway I bet I would notice short circuit spark..
Regarding the DC output test - You are right, I think
I misread the instruction - and checked on the disconnected
voltage regulator connector, measuring on the battery
with engine on, gives required values, so it works now, thank to your explanation! :-)
As I already ordered next voltage regulator,
assuming I fried it, seems I'll one one spare :-)
One more buell on the road, thanks again!

[DeTe]

Em, a little tip for future readers.. when you assembly
primary cover, do not forget tighten drain screw,
I left it loosed in cover and lost a few ounces
of new transmission fluid - as the bottle it is sold
has exactly 32 ounces ( 946 ml ), I need to buy
another one to fill.. :-)
Regards,
DT

[Rays]

That is good news. I am really impressed that you were able to rewind your own stator. [up]

Did you take any photos of the process?

[DeTe]

Well, I don't have photo camera, just cellphone, I don't need photo camera in general,
I did just few shots on disassembled engine, similar to these one may find with google, nothing special I guess
(primarily for assemble help view purposes )
similar to e.g. these

http://www.buellbabe.com/tag/alternator/

http://bogadr.fotosik.pl/zdjecia/2

(the 2nd link is actually my friend's lightning, not too
many buells here in Cracov ( my little farm - ully and bolt, and his lightning, per 1 000 000 people ;-)
BTW I'm really happy I didn't need to disassemble
gearbox itself :)

I still didn't do general wall & floor renewal
in my garage, that keeps me away from posting pictures ;-) I'll post it on my bikes site,when I solve finally
another issue ahead.. Posting as new thread, ugh.