Need New Charging System For `91 Fat Boy - Cycle Electric Good?

[Coaster1948]

Need New Charging System For `91 Fat Boy - Cycle Electric Good?

Okay, I'll try this again. All of my previous typing went by the wayside when allowing pop-up's. Man!

Here's the situation.

I've been in denial of needing a new charging system for a year now but, yesterday was the straw that broke the camels back.

Went out with the Bride and we only made it 62 miles before stopping for a snack. Went to start it and CLICK...............argh.

Well, I've had that happen before and thought that maybe I had a bad connection. Troubleshot and found that the regulator/stator plug was partially disconnected. Fixed that and figured I'd fixed it. Nothing else wrong except that the output was 12.2 volts. Just below requirement. I don't get to ride much because of back problems but, when I do, I don't need to break down away from home.

Back to yesterday:

When it wouldn't start, I was prepared. I had an extra older battery in the saddlebags so, I changed it out and we got home fine but, it absolutely cut our ride down to nothing. What a bummer.

I've been doing a lot of research the last few hours since and have read a lot on Cycle Electric Inc's 3 Phase, 38 Amp, alternator kits. They come highly recommended by the rags I read. www.cycleelectricinc.com (Alternator Kit P/N CE-62A)

I absolutely will not purchase a replacement for mine unless its made right here at home. In The U.S. of A. Sorry Teddy! You loose again!

Cycle Electrics' system falls right in there and ACCEL as well but, I'm more for the small Mom & Pop manufacturers like Cycle Electric Inc.

My questions are:

1. Anyone know anything about the installation of their CE-62A Alternator Kit?

2. Anyone had any problems with their systems?

3. Any other choices out there other than these two that are at the front of the technology spectrum with high quality systems?

4. Best place to purchase their kit, price wise?

I don't have a lot of cash to throw away and can't afford to be FORD (found on road dead) in the saddle because of a discharged battery. Carrying an extra is behind me now. Time to face the fact that it's time to upgrade.

A little history as to why I want the 3 Phase, 38 amp system:

Installed upgrades like H4 halogen bulb in Road King Styled headlight nacelle, Lazer Star Halogen Shorty Run/Turn lights with their converters for rear lighting, spots and run/turn flat side run/turn on light bar on front.

And their 3 Phase system runs cooler with less drag on the engine. I think it's a win-win solution.

The thing I'm trying to say is, with all of this extra lighting, the 32 amp system still might not supply everything needed considering the halogen lights and spots all at one time. I could spring of an OEM system but, I wouldn't have a warm fuzzy about it.

Where I live (Georgia), we have to ride with a headlight on at all times. So, there's a constant load on the charging system.

Anything you guys can interject on other solutions short of converting back to filament lighting, will be greatly appreciated. It's an old scooter and everything I have to replace, I like to replace with OEM parts or higher quality aftermarket ones made here at home.

Let me know your thoughts and experiences with Cycle Electrics systems. I really don't mind paying the extra cash for quality and Made in America parts because the replacement cost out way buying two or three more cheap overseas systems.

Thanks for any of your input y'all.

Coaster.............out.

[frisco-rigid]

Coaster

It does sound like the system is going out but first, have you checked the AC Volts Out-Put of the Stator ..
Have you checked for continuity between the Stator female Pins AND from those Pins to Ground.?
Do you know how,, it's in the manual.. I ask cuz you Did Not say if you did those tests or not..
If the stator passes all those simple tests then it's Not the Stator,, could be the VR or the Batt.. Save some dough maybe..!

I have used Cycle Electric many times and for many years.. If memory serves I'm running 2 of them now.. I've also used Accell groups of times too, hey, they're both good from my experience..
There is Nothing diff about installing the 38amp 3 phase system, they all install identical.. You're buying the whole kit so No probs..

If you haven't already,, add up your Amps.. Rule of thumb is no more than 80% of the systems out-put..
Remember, if a light system doesn't already state the amp's then it's--- wattage divided by 12 volts..
Running a waaay lota amps can stress the entire wiring and CB's, relays,, your call..

Have a ball

[Coaster1948]

Frisco-Rigid, thanks for your imput on those two manufacturers.

I'm not wanting to go too high with the amperage. 38 will be just fine with all of the lights I've got installed. 32 amps I'm afraid won't cut it. Not going to spend a lot of cash on something that's not strong enough and be out that plus more to upgrade.

Yes.....I've done every test plus some and not just once. The only thing I didn't do was add up the amps for all of them to see what the requirement is.

A dude told me to check out an OEM Police charging system for my ol' `91. Of course, my luck, they don't make them any more and from what I've read just a little on them is that they're rated at 40 amps. Don't know what they were back in `91. No reference to them in my repair manual since they're usually touring models.

I'll have to get more info on Harleys' unit before I spring for it.

Thanks for your imput as I stated above. Experience on something like this is something I lack but, am like a sponge. I'll get the system that works within my budget and won't give me more grief.

Coaster.................Out.

[Gas Man]

I would check out a Compu-Fire 40 amp 3 phase system

[Coaster1948]

Hey Gas Man! Thanks for your $0.02.

Well, I've taken and rerouted the primary wire off of the regulator that goes to the main CB (30 amp), and spliced it with another wire and hooked it directly to the positive post of the battery. That was my Wrenchin' Buddy's idea that I trust more than anyone. Anyway, he told me that after doing that, to turn on every light on the scooter to see if the CB would break contact.

Well, I did that.

I even went above his instructions with turning the spots, with the low beam on, a turn signal while applying the brake light.

The CB (Circuit Breaker) didn't break contact (pop in the Aviation World).

When looking back on my troubleshooting results, and the CB not deactivating with all lights on, I've come to the conclusion that with a 12.4 VDC output on the alternator, and other criteria, that I've got a weak charging system.

Now, with the test I did, the engine wasn't running so, with that in mind, I'd think that there could possibly be an additional draw on the charging system enough to cause it to not charge the battery up at all. How much more, I'm not sure. I'm not a Rocket Scientist.

So, that's where I stand. Not completely sure that my light draw, along with the engine draw requirement, isn't actually more than it can put out. So, a new system is in order.

As far as Cycle Electric, Inc's systems, I think that I'd rather go with them first. Why?

Because it's a quality "Made in the U.S.A." company that has a proven track record. And, it's like a Mom & Pop operation. I do know that Compu-Fire is also made here in the Good Ol' USA as well.

Let me interject this.

When I went to the Cycle Electric site, I tried to download their "Technical" page. It didn't work. Nothing but computer code with the original text interjected into it came up.

So, I copied it all. Then formatted it into a PDF file.

I contacted the owner, Karl, and advised him of his web page issue. He does all of his web page maintenance himself, by the way, and wasn't aware of an issue with it not coming up for us prospective customers.

Well, that was enough for me. Anyone that's that hands on with everything to do with his company, and that has an excellent track record as he does, made me think, why.....would I want to go to another supplier. Even Compu-Fire at that?

I realize that their products are made here in the U.S.A. but, they're a sub-division of a parent company. Whereas, Cycle Electric, Inc is not.

I absolutely believe in supporting our Countrymen and Women but, when you look at the quality of each product and have to decide which is the better choice, and who needs my dollar more, and has an excellent track record to boot, hands down, Cycle Electric, Inc. gets my hard earned cash.

Oh yea, another thing. When I talked to Karl first off when HE answered the phone, I was giddy like a kid and I'm 60 years old. I couldn't believe that the owner would actually be answering the phone. When was the last time you had that happen?

I told him the web issue and offered to send him my PDF rendition of the Tech page. I told him that I didn't expect anything in return for doing it for him and that I totally understand his issue with the tech page and just wanted to help him out because, interject sappy here, since he was in need, I thought I could help him out.

I feel, that what ever it takes, for all of us, to ensure that our countrymen/women stay in business and I can help them out, I'll do what ever it takes within my ability. I couldn't do anything worse than what he had available on that Tech page. He's into manufacturing charging systems. Not web pages. Right?

'Nuff said why I'd go with his product instead Gas Man.

Thanks for your input though. At least I know that there's one other company out there in our country that's supplying us with the goods we need. But, for how long without our support? I buy American products when ever that's possible.....and if it's a few dollars more, the better. I know that it's supporting our way of life. Lets' not go there on Accel Charging systems. My Wrench Buddy wouldn't touch one of theirs.....

Coaster..........................Out!

[Gas Man]

No worries... you choose what you want. I am fully behind you on the buy american. I just wish more people were like us (and I'm sure like most here on this site). I know I work hard to have 2 american cars and 2 american bikes in my driveway. But remember I'm from Detroit and we know more than anybody what it means to support USA auto. Especially, how the country song says... wall st is shuttin detroit down.

On more trouble shooting... why can't you just measure the battery voltage with the bike off. Should be in high 12's. Then start the bike and measure it and it should be around 14. If not, test the voltage regulator side of the circuit breaker and see if its 14 on that side but just not the battery side. If so the CB is poped or junk if it wont reset.

If not 14 on either side... test the stator power coming out of the front of the motor... it would be test AC voltage. I don't remember off the top of my head what volt it discharges... If isn't putting out the proper power, then the weak link would be the VR.

That all being said, with the understanding that all the wires and connectors are sound.

Making any sense?

[Coaster1948]

Originally Posted by Gas Man

No worries... you choose what you want. I am fully behind you on the buy american. I just wish more people were like us (and I'm sure like most here on this site). I know I work hard to have 2 american cars and 2 american bikes in my driveway. But remember I'm from Detroit and we know more than anybody what it means to support USA auto. Especially, how the country song says... wall st is shuttin detroit down.

On more trouble shooting... why can't you just measure the battery voltage with the bike off. Should be in high 12's. Then start the bike and measure it and it should be around 14. If not, test the voltage regulator side of the circuit breaker and see if its 14 on that side but just not the battery side. If so the CB is poped or junk if it wont reset.

If not 14 on either side... test the stator power coming out of the front of the motor... it would be test AC voltage. I don't remember off the top of my head what volt it discharges... If isn't putting out the proper power, then the weak link would be the VR.

That all being said, with the understanding that all the wires and connectors are sound.

Making any sense?

Hey Gas Man.....

Detroit huh? Cold country. Used to live due south of ya in Southern Indania. Cold there too but, now, in central GA.

I've done all of the checks you mentioned except for measuring volts at the CB. Everything seems to be kosher except for the regulator and an intermentent reading of VAC from the stator. There's an issue with the stator having been overheated before I bought this POS. So, with the primary oil leaking out around the stator plug, and the intermentent readings and low voltage and amperage charge at the battery, it's time to upgrade. It will be the last major component that I'll have replaced then. Everything else has been replaced on the electrical side, rebuild on tranny and engine top end.

So, to make it dependable I've got to replace the whole charging system and why not go to a higher output (amp wise) system? Makes sense to me. 32 amps is OEM rate on `91 Softails as you know and going to a 38 amp system will give me a warm fuzzy......LOL! Plus, I want the newer technology of the 3 Phase system as well.

I don't have the figures on what readings I got while troubleshooting it, if I haven't misplaced them somewhere, I'll let you know what they were. Sucks to get old. I've got CRS......(Can't Remember Sh*t).

Thanks for you input Gas Man. Tell all of the folks up there in your parts, good luck on the Auto Business getting straightened out. God help us all......on that one.

Coaster................Out.

[Gas Man]

Coaster... I couldn't agree with you any more.

Upgrades are always good and add to your sense of confidence in your bike.

Thanks for the good luck. This spring/early summer I know at least 6 of my buds that have been laid off due to all this stuff. I have never seen it this bad.

[Coaster1948]

Originally Posted by Gas Man

Coaster... I couldn't agree with you any more.

Upgrades are always good and add to your sense of confidence in your bike.

Thanks for the good luck. This spring/early summer I know at least 6 of my buds that have been laid off due to all this stuff. I have never seen it this bad.

Gas Man,

I had forgotten that after retracing my steps mentally, that I had indeed taken readings of output at the main CB (silver post where the regulator main wire hooks up) and found the reading there below the borderline requirement but, just by a little.

I still can't find the paper I wrote everything down on. I'm not the best organized person in the world...LOL! Got a memory like a steel trap....when it's something I want to remember. Charging system readings? Not so much interest........

With all that I have done to make this scooter dependable, this will be the last, at least major upgrade I do until I decide on some engine upgrades I'd like to do.....said with tongue in cheek, to it later this coming winter.

I really hope that every one of your buds finds something around there. It's bad everywhere. I don't even know where I could suggest anyone to look for a job. Specialty wise that is. Check this site out and pass it on. There might be something for them elsewhere. F&M Fabricating & Metalworking

They might not find anything listed there at all but, if they'll check into it deeper and all of the other divisions of the site, they might be able to come up with some companies within the area or close to it, that need their skills. Just an idea. Networking is what it's all about Gas Man as you well know. I only wish the best for all that are caught up in the quagmire. It looks as thought the ship is sinking if something doesn't happen real soon. Short of a revolution of course but, I wouldn't throw that out with the dishwater.

Be safe and good luck in what you're into Gas Man……and thanks again for your input.

I'll just try like others are doing.........to tread water.

Coaster.................out.

[Gas Man]

Will pass it along Coaster. You're right networking is well. I have been trying to get one bud a job at either my company or one of my customers... but its not going so well.