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Discussion Starter #1
Hello to all,
I am the guy who bobbed my 2003 750 and has been fighting with her the whole time. I purchased a bike with a known bad stator...but the price was right for a bike in very good condition. I read about the tuxedo modification, and without hesitation, I gave it a shot. However, I used a cheap replacement from EBay...first of many mistakes with my nightmare. The cheap stator came apart and ruined my magneto...which ended up requiring an engine pull anyway. Here is what I ended up doing to the bike over the next few weeks (or months) to the electrical system.

1. Tuxedo Modification
2. New Caltric Stator and regulator (big mistake)
3. New Shorai Battery
4. LED Turn signals
4. New Headlight
5. Bobber Tailight
6. Switched Cooling fan
7. Engine pull to change magneto
8. NEW Stator from Ricks Motorsports (in case the previous stator was grounding with heat)
9. New Mosfitt Voltage Regulator
10 New relocated ignition switch
11. Blue wire modification
12. Two wire modification

Still, the bike would not charge. She would run great on a fresh charge, but suddenly it would discharge the battery and kill the bike. Even blew the 30 amp fuse one time. Was driving me crazy. As suggested by someone here on this forum...I went back and checked every single wire connection I made. Checked for cold solder joints...checked for failing heat shrinks. Checked my grounds over and over. I tested the stator...checked out fine...but I changed it again in case it was grounding out under extreme heat. I was about ready to drive my bike into the Indian River out of frustration.

Yesterday, I added oil to the bike (after the last stator change) Then, I grabbed the battery and dropped her into place under the seat. Suddenly, I saw it....plain as day. The positive battery terminal was almost touching one of the bolt lugs on the frame. Then I shook the battery...and it did touch creating a spark. If I would have taken the time to install the battery terminal straight to begin with, and actually made sure the red rubber terminal cover was pushed into place correctly, it never would have happened. The battery was actually vibrating when running, then, grounding out to the frame and killing the battery suddenly. With simple adjustments, the bike fired right up and rode perfectly for several hours.

Moral of this story is: Never assume anything. Don't be stupid like me and overlook something as simple as this. Obviously the bike needed a new stator and regulator anyway, but I could have saved myself a lot of headaches along the repair process. I am ashamed of myself. I am supposed to be a mechanic.

My son is due home from overseas in 30 days after this latest deployment, and I will be giving this bike to him He has spent the past several years protecting me here in the US, so giving him the bike is the least I can do for him. #GoArmy #FightingMan
 

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mayor of Narnia
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248 Posts
thats great and thank your son for his service for me
 

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FREEBIRDS MC CENTRAL NY
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16,268 Posts
Yes you may be a mechanic but I'll bet money that you also may be a human as well;)
 

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Tinkerer
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572 Posts
We all make mistakes, none of us are perfect. Glad you got it sorted in the end and what a fantastic present to give to your son!
 

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2000 VN 750 Senior Member
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2,501 Posts
As mentioned previous to this post, give my thanks to your son along with our respect and admiration for what he is doing for this country. Don't worry about making a simple mistake. I am sure you learned a lot more because of it than you would have if it all fell into proper order on its own. The fact you realized your mistake, corrected it and were willing to tell the rest of us about it shows some real honesty and class. I am sure your experience will play back in the heads of many here when they have a similar unfound situation. I know I will remember to look for the simple and obvious before replacing and tearing apart too much at first.

Good luck to you and your son and I hope you both get many miles together.
 

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8,431 Posts
Looks good, very unique. A video of those flappers in action might be awesome.

Going to give my battery a look too. I know the hold down strap is off of it, some of those giant speed bumps (frost heave) we have might have made it pop up. It's not that you missed the problem that matters, but that you found it ... and also shared it.

I'm sure your son will be thrilled, as will you.

Two wheels down! Let us know how the unveiling goes. 30 days, here's hoping for great weather.

 

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Discussion Starter #10
Also...I am not really a professional mechanic. I am really a Business Owner and High School Football Coach. I am just a shade tree guy whos hobbies are rebuilding / repairing boat motors and engines of all types. This whole motorcycle stuff is new to me. Thanks for all your help.
 

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Registered
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Nice work! that is one awesome present for your son.
Well deserved for all he is doing for our country and homeland...thank him for me please. and thank YOU for raising a great American...and sharing your project with us.

all I can say is....WOOOOOOOO!!!
 
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