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Pso
| | Posted on Saturday, May 02, 2009 - 10:07 pm: | 
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Just replace the connector with a crimp and shrink connector. The female end of the 77 was starting to show the burn problem. Had VR replaced last summer.I noticed that my GPs and also radar detector registered a higher voltage reading once I swapped out the connectors. |
J0hn0tt0
| | Posted on Tuesday, May 05, 2009 - 01:43 pm: |
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quote:VR - part # Y0302.02A8
Stator Assy. - part # 29971-02Y (if needed) this could be your problem.
Further T/S needs to be done. I'm sure both parts are expensive.
FYI, for your battery voltage?
@ 100% charge it will be 12.7/
@ 75% charge it will be 12.6/
@ 50% charge it will be 12.3/
@ 25% charge it will be 12.0/
0 charge it will be 11.8.
Give me a PM and I can help you further troubleshoot. In my manual there is a procedure for checking both the VR and the Stator/rotor assy. To much to type here.
Dude, you should get the service manual. It explains the charging system well and provides the troubleshooting too.
I'll post where I picked up mine, as well as the parts catalog. It was cheaper than at HD or other regular/normal source
Snojet, thanks for all the info. I, actually, didn't have the service or parts manual, but just placed an order through LSHD1 for both at great prices. 
I plugged in those parts number into Chicago Harley's website and 2 stators came up with that part number, ranging from about $105 to $115, so it's not too bad. The VR part # that you supplied didn't come up on their site, though.
I'm also looking into buying another battery, since my bike came with the battery DEAD and it can be a little lethargic when turning over the bike. I think it was in the 12.6 range, which is 75% charged according to your chart. I keep the battery on a battery tender, though.
By the way, how do I send a PM on this site? |
Mnrider
| | Posted on Tuesday, May 05, 2009 - 04:03 pm: |
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Just click on the persons name on the left.
Good luck JOhn.
OH you can read the profile too! |
Ksc12c
| | Posted on Tuesday, May 05, 2009 - 04:28 pm: |
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After reading this post and several others I decided to check the dreaded 77 connector. I pulled it apart and to the naked eye everything looks O.K. No melted plastic or burn spots. The Bikes still under warranty and I'd hate to replace the connector while its still under warranty. The warranty expires in a couple of months and with my luck it will fail the day after the Warranty expires. I probably should at least order the new connector |
J0hn0tt0
| | Posted on Tuesday, May 05, 2009 - 04:36 pm: |
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quote:After reading this post and several others I decided to check the dreaded 77 connector. I pulled it apart and to the naked eye everything looks O.K. No melted plastic or burn spots. The Bikes still under warranty and I'd hate to replace the connector while its still under warranty. The warranty expires in a couple of months and with my luck it will fail the day after the Warranty expires. I probably should at least order the new connector
Honestly, just go to Home Depot and get some crimp or solder connectors. MUCH easier than the service kit. IMO, the only time the service kit is anything near useful is if you order a new VR and it already comes with the new plug pre-installed, therefore leaving you with only crimping the one other plug. |
Snojet
| | Posted on Tuesday, May 05, 2009 - 04:45 pm: |
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Glad to help. I will check my parts catalog again and see if I fat-fingered the VR number. As for the PM thing. Click on my name, my profile will appear in a new window. At the bottom is a title that says "Click Here to send a private message to Snojet". Click there and that message will be sent to my personal email. When I told you to PM me, it was so I could scan (if my computer and I can get along) that section of the manual that refers to your problem, then I would email it to you or fax. |
Pso
| | Posted on Wednesday, May 06, 2009 - 04:08 pm: |
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I agree with JohnOtto. it was an easy job. After last summers episode with a failed VR/#77 connector, I purchased a spare VR so that I wouldn't be stranded in some far away place. I marked the wires on the spare vr and cut off the connector and put on heat shrink crimps. Now if I have another failure (which I doubt becaue the connector will not short out), I have a spare that just needs to be crimped in. also the crimped connection takes a lot less space. I also attempted the kit, It was a pain and I would have to have purchased another one for my spare so I just went the other route. |
J0hn0tt0
| | Posted on Wednesday, May 13, 2009 - 03:01 am: |
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Success!
All my packages came in today and I fixed up the bike. I now have service and parts manuals so that I can be much more independent in diagnosing issues from here on out.
Turns out that all that was wrong was that the VR fried. I ran some tests on the stator and it's doing fine. I replaced the VR, started up the bike, and my LED battery meter went solid green within 2 seconds. The battery hovers around the 14.5V mark, regardless of RPM. All is well again.
Time to RIDE! |
Pso
| | Posted on Thursday, May 14, 2009 - 12:37 pm: |
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Mine hovers around 14V. but that is with Radar detector, xm radio, gps and both headlights on. Before I fixed the partialy melted connector it was closer to 13.3-.6V. I think I caught it just in time. |
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