Early TC88 Touring Stator

If you have a fuel injected touring or police model made between 1999 and Jan. 2001 beware. If your charging system hasn't gone belly up, it may sooner than you expect. The problem is that the stator used is for a 38 amp system, these bikes have a 45 amp system. How'd they do that? They put a beefier rotor with stronger magnets over the same stator used on both the 38 and 45 amp systems. The inevitable result is higher temperatures produced by the higher output which will kill the windings on the stator.

Harley is well aware of this problem since they put out a new upgraded stator (part #29987-99A) and Service Bulletin M-1111 explaining the problem. No there's no recall on this but if you have to change your stator, make sure you keep all your receipts just in case. What's worse is that H-D is still selling a kit to convert the 38 amp to the 45 amp with, you guessed it, the bigger rotor while you re-use the inadequate stator.

The so-called "New & Improved" stator... It appears to have thicker wire and a neater job on the windings. Replacing the stator isn't hard if you follow the repair manual and have the right tools.

You will also need to replace your Main circuit breaker, it is a 40 amp in these models, and when upgrading your stator to a 45 amp system will cause an open circuit at some point causing a "quit while riding" situation. The main breaker needs to be upgraded to a 50 amp.

The three service bulletins are M-1111 and M-1151, M1151-A