| Author | Message | ||
     Skifastbadly |
So my voltage regulator goes out and strands me. I have it replaced at the dealership. Research here and on advrider.com indicates this is a know problem, and to check my "77 connector". I checked. It's partially melted. Since this seems to be common, and I don't want to get stranded out in the boondocks, I call the dealer. He 'never heard of this problem and there's no bulletin on it'. I call HD customer service. Same answer...with the additional catty "you can't believe what you read on the internet" comment. So, how do I get this fixed? Field engineer a solution? Does Buell at any level acknowledge this as a problem and is there a fix? Thanks | ||
| Svh |
Call Buell Customer Service as I am sure they have heard of this common problem. | ||
| Skifastbadly |
If there's a Buell customer service that's separate from HD customer service, I don't know about it. I called 414 343 8400. Do you have a number specifically for Buell? Thanks | ||
| Hughlysses |
That's the right number (listed here on the "For the Factory" forum"). You can also find it in your owner's manual. | ||
| Skifastbadly |
Well, that's the number I called. "We are unaware of any such issue. You know how the internet is, it could just be five guys talking..." I think I'll just rewire the thing, use some submersible pump wiring and hope that I never have to worry about it again. It's already out of warranty, and a trip to Home Depot for the couplings and installing them will surely cost less time and money than riding back down to the dealership explaining the problem, having them tell me they don't have a coupler in stock, waiting for one to come in, and hoping they don't just create the same issue all over again. | ||
| Jlnance |
See here: http://www.badweatherbikers.com/buell/messages/142 838/447122.html | ||
| Doncasto |
Y1312.02A8 VOLTAGE REGULATOR CONNECTOR SERVICE KIT Retail Price:$19.40. . . . courtesy of Froggy at the link noted above. | ||
| J0hn0tt0 |
http://chicagoharley.com/shop/product_info.php?man ufacturers_id=10&products_id=466110&osCsid=a806296 a04721fe358f9674d85696bdf | ||
| Hexangler |
I found this problem on mine, as well as, a worn red wire. I'm taking my connector out, and soldering the applicable wires together and finishing with heat shrink and electrical tape. Priceless. | ||
| Hexangler |
It looks like Buell engineered (stuffed) no less than five connectors in this very tight engine cavity. Guess what, it's crammed, the wires are kinked to fit, with heat and vibration they stress, chaff, and fail. Never heard of it before? BS.   | ||
| Court |
How many folks here have had that happen? Has someone counted the reported cases? | ||
| Froggy |
First time Ive seen that wire have a issue. Thats not the 77 connector, and the 77 connectors issues is in the plug, not on the wires outside it. | ||
| Hughlysses |
We should try and take a tally; I'd say there have been at least 10 cases reported between here and advrider. One Badwebber went so far as to document the inspection/repair procedure: http://docs.google.com/view?docid=d4rbxwr_20dq5khf. At any rate, Buell has to be aware of the problem as replacement voltage regulators for 06/07 Ulys use a new-style plug and come with a matching plug to be retrofit onto the bike's wiring harness. Although we haven't seen it yet, the kit Froggy mentions appears to be an upgrade plug set which can be used to repair a bad 77 plug without replacing the VR. I had a battery go dead and the bike die 60 miles from home as a result of poor contact in the 77 connector but the connector didn't melt (I guess I caught it early). The document linked above saved my vacation last summer. The 08/09 XB's evidently use a different connector which made the problem go away. (Message edited by hughlysses on April 16, 2009) | ||
| Hexangler |
Thats not the 77 connector...Then what is that connector? The red wire is hot (positive) right? So, this could be a reason for my battery/charging issues? Any problem with permanently connecting these wires and removing the plug(s) as I suggested above? | ||
| Froggy |
Without the service manual I honestly could not say what that wire is. The 77 connector is a 2 pin black connector, and is stuffed behind those 3 pin connectors that are clearly visible in your photo. Here is mine that partly melted:  | ||
| Hughlysses |
Hex- I wouldn't think that's your problem, because there shouldn't be anything nearby for that exposed wire to ground on. The pulley cover (which you've removed to photograph the plugs) is plastic. IIRC the 77 connector is buried behind all that stuff. It is not real easy to get to. If you haven't checked it yet, I highly recommend you do so. All those plugs do take up a lot of limited space. | ||
| Hexangler |
Thank you guys very much, I will check all when I get home tonight.  | ||
| Smolt |
Hexangler asked: "...Then what is that connector?" Based on Figure 5 in the linked Google doc, the gray three pin connector is the stator connector.  | ||
| Hexangler |
Hummmm, stator connector, could be the cause of the charging problem after all. I need to take a closer look at the fray, possible broken wire inside, and possibly a short to ground. I've got the parts manual and the repair manual, so I'll check which connector that is as well. Thanks Smolt. | ||
| Court |
Frogster: You want to volunteer to gather and consolidate the data and get it and all the photos to me I'd like to make sure the platform folks are at least aware of it. Sometimes these things are or are not as they seem but I need data. For me trying to simply call B.S. on them will shut any effort down. I check out Advrider about twice or three times a year and would not have seen anything there and the subject of this thread, looks to me anyway, is something we've not seen before. I'm busy until May 20th, but it someone wants to get the raw data to me I'll write it up. Court | ||
| Skifastbadly |
When I pulled mine apart the other day there was melted plastic. I've actually ordered the replacement plugs online, but I don't think they'll be here by this weekend, so I'm seriously thinking about just using submersible pump connections and leaving it at that. In either case, when I pull it I'll photograph it. I'll post it here. | ||
| Froggy |
Court, I believe Buell is aware of the issue. There is a service kit to change failing 2 pin connector right from Buell. "Y1312.02A8 VOLTAGE REGULATOR CONNECTOR SERVICE KIT Retail Price:$19.40" Or thats what I have heard it is, nobody that has bought one has reported back to say what it really is. The VR's were recently changed to come with a slightly different connector that should prevent the issue in the future. The issue Hexangler has is something else. If you want I will still collect all the data, but I see it as pointless as its been addressed and any failures from here out are people with the old connector setup. | ||
| Hughlysses |
Yea, I think the problem has been addressed by the factory. It's just a little disconcerting to see a guy like Skifastbadly ask the dealer and Buell Customer Service, and get the "Nope, we never heard of that" response. If Customer Service could be made aware of the repair kit, I think the problem would be solved. | ||
| Ducxl |
Really funny  I'll watch MY connector on my XB.It's easy to inspect.Even funnier,i just replaced my connector between my voltage regulator and stator last month on another bike.Once corrosion sets in from moisture,oxidation occurs,and resistance goes up and melting happens.   use dielectric grease on assembly | ||
| Hexangler |
Whenever I call any customer service department, and I feel things are not going to my satisfaction, I take detailed notes, name, badge number, and then talk to the CS person's supervisor, and then go over the whole thing again until the question is answered to my satisfaction. Buell is no exception. | ||
| Jlnance |
Then what is that connector? The red wire is hot (positive) right? Those wires go to the 3 phases of the stator. They carry AC. It is not until they are rectified inside the voltage regulator that they are turned into DC (negative and positive.) That DC is coming out through the 77 connector. | ||
| Hexangler |
I checked the 77 last night, and it looks new, so I'll check my ground connections, and do the electrical diagnostic prescribed elsewhere on BadWeB. Thanks again. | ||
| Mermark |
I have an 06 and a 05 firebolt and it happened to both of them first the time it happend was to the 05 in August of 07 and just recently with my 06 | ||
| Jamesg |
Similar story here. Had the charging system on my 06 Uly die yesterday. Stator passes ACV test, but the Regulator is only putting out 2.3 VDC regardless of RPM. My 77 Connector has similar melting on the positive pin. The metal isn't burnt away, but the plastic melted around it. Sigh... I guess HD standard voltage regulators aren't compatible with the XBs are they? |
