![](https://motoinstruction.ru/img/harley/12/118327.jpg)
Figure 6-89. Voltage regulator: 1. Voltage regulator; 2. Screw (2); 3. Stator pin connector [47A]; 4. DC output pin connector [77A]; 5. External latch
Note. This part cannot be repaired. Replace upon failure.
Removal: XL models
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
Note. Never pull on wiring when unplugging voltage connector.
2. Unplug stator connector [47]. Lift external latch on pin housing and separate connector halves.
![](https://motoinstruction.ru/img/harley/12/118328.jpg)
Figure 6-90. Separating stator connector housings: 1. Pin connector [47A] (voltage regulator side); 2. Socket connector [47B] (stator side); 3. External latch; 4. Open latch; 5. Separate socket connector from pin connector
3. Lift external latch on DC output connector [77] pin housing and separate connector halves.
4. See Figure 6-91. Remove screws (2) from locations at top and bottom of voltage regulator. Remove regulator from vehicle, carefully threading harnesses through opening in regulator mounting bracket.
![](https://motoinstruction.ru/img/harley/12/118329.jpg)
Figure 6-91. Voltage regulator location: 1. Voltage regulator; 2. Mounting screw (2)
Installation: XL models
FASTENER | TORQUE VALUE | |
Voltage regulator mounting screw | 36-60 in·lbs | 4.1-6.8 Nm |
1. Position voltage regulator close to mounting bracket. Orient regulator so cooling fins face forward and wiring harnesses exit regulator body toward right side of vehicle.
2. Route stator harness down along between right frame downtube and body of voltage regulator. Route stator harness connector [47A] toward right side of vehicle.
3. Mount voltage regulator on mounting bracket between frame downtubes and secure with mounting screws at two locations. Tighten to 36-60 in·lbs (4.1-6.8 Nm).
4. Plug stator connector [47A] into socket connector [47B]. Fold external locking latch over and lock in place.
5. Plug voltage regulator DC output connector [77A] into socket [77B]. Fold external latch over and lock in place.
6. Install main fuse.
7. Test charging system. See the electrical diagnostic manual.
Removal: XR 1200X
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
Note. Never pullon wiring when unplugging voltage connector.
2. See Figure 6-92. Unplug stator connector (4). Carefully pull barbed cable strap (3) from frame.
![](https://motoinstruction.ru/img/harley/12/118330.jpg)
Figure 6-92. Oil pressure switch: XR1200X: 1. Oil pressure switch; 2. J-clip; 3. Barbed cable strap; 4. Stator connector [47]
3. See Figure 6-93. Cut cable strap (1). Lift external latch on connector and separate connector halves.
![](https://motoinstruction.ru/img/harley/12/118331.jpg)
Figure 6-93. DC output connector: XR 1200X: 1. Cable strap; 2. DC output conector; 3. Oil pressure switch, neutral switch harness; 4. Oil filter
4. See Figure 6-94. Remove screws (1) from locations at top and bottom of voltage regulator (2). Remove regulator from vehicle, carefully threading harnesses through opening in regulator mounting bracket.
![](https://motoinstruction.ru/img/harley/12/118332.jpg)
Figure 6-94. Stator wire routing: XR 1200X: 1. Screw (2); 2. Voltage regulator; 3. Stator wiring; 4. Cable strap
Installation: XR 1200X
FASTENER | TORQUE VALUE | |
Voltage regulator mounting screw | 36-60 in·lbs | 4.1-6.8 Nm |
1. See Figure 6-95. Position voltage regulator close to mounting bracket (1). Orient regulator so cooling fins face forward and wiring harnesses exit regulator body toward right side of vehicle.
![](https://motoinstruction.ru/img/harley/12/118333.jpg)
Figure 6-95. Voltage regulator wire routing: XR 1200X: 1. Voltage regulator mounting bracket; 2. DC output connector; 3. DC output wires; 4. Stator wires
2. Thread DC output wires below mounting bracket. Route DC output connector (2) toward left side of vehicle.
3. Route stator wires (4) down along between right frame downtube and body of voltage regulator. Route stator harness connector [46A] toward right side of vehicle.
Note. Verify that the wires do not get pinched between bracket and regulator.
4. Secure voltage regulator on mounting bracket with mounting screws. Tighten to 36-60 in·lbs (4.1-6.8 Nm).
5. See Figure 6-96. Connect stator connector (1) and fold external latch over and lock in place. Secure stator connector to bracket with barbed cable strap (3).
![](https://motoinstruction.ru/img/harley/12/118334.jpg)
Figure 6-96. Stator connector: XR 1200X: 1. Stator connector; 2. Cable strap; 3. Barbed cable strap
6. Secure stator wires to right frame down tube with cable strap (2).
7. See Figure 6-97. Connect voltage regulator DC output connector. Fold external latch over and lock in place.
![](https://motoinstruction.ru/img/harley/12/118335.jpg)
Figure 6-97. DC output connector: XR 1200X: 1. Cable strap; 2. DC output connector; 3. Oil pressure switch, neutral switch harness; 4. Oil filter
8. Secure DC output connector (2) along with oil pressure switch, neutral switch harness (3) to voltage regulator bracket with cable strap (1).
9. Install main fuse.
10. Test charging system. See the electrical diagnostic manual.