The Chopper Compendium

I've been riding several times this year after rebuilding the Super E and putting in a new battery. (92 FXLR)

Due to work, the bike sat a few days. I came home a few days ago, and when I started it, it seemed a little sluggish to turn over, but fired up and sounded right. I had a meal at a diner a couple miles away, and the bike wouldn't start. Had to get a jump start to get home, and the bike died after I parked it.
I charged it up today, tightened battery terminal bolts, added gas, and had a 10 mile ride. Got home and started checking the system.

Using a cheap multi-meter, got 14.27 VDC approx at battery terminals while running.

With regulator disconnected, motor and ignition off, I get these results...

Grounded stator check:
Stator plug to ground, no continuity either terminal. Indicates stator is NOT grounded (thats a good thing)
Stator resistance check:
Stator terminal to terminal, I read 0.4 to 0.5 ohms (not good, should be 0.1 to 0.12)
Stator AC output check (yes, AC, not DC):
Stator terminal to terminal with engine running, alternator should produce 16-20 VAC per 1000 rpm. I don't have a tach, but the meter responds nicely when revving the motor, from about 16 up to 66.

Testing done per HD Service Manual for 1991 FXR/FLT models.

Preliminary conclusion: Either my stator is shorted, providing too much resistance, or my cheap meter and I are doing something wrong.

I have more tests to do before I decide what to do. I'll try a different meter, and also check the regulator, before i tear into the primary system.

Well all I might say is that recently had a similar problem...turned out the inside of the positive cable from the battery was rotton?

I have also had problems with the cables being corroded on the inside of the jacket where you couldn't see it I had this on both cables

I have had bad ground connections cause weird problems before.

Thanks for the replies, it seems like the loose terminal (ground side) was the culprit.
I've been doing some short test rides, everything seems OK.
Today, at idle, I was reading 14.26 VDC at the battery terminals.

I'll be keeping a close eye on it tho.

Next step is to get some bags hung so I can carry a small tool pack with me.

hate those 10 mm battery bolts never seem to stay tight

Agreed, saw some on a Triumph Tiger today that go in from the top and are slotted. Might look for some.

HD had a recall, the regulator was not properly grounded.
Also, the alternator plug, some years didn't have a spring clip to hold it down, J&P sells them.

I've had more problems because of not having one of those clips. That plug can be a little loose, not very noticable, and all of a sudden you don't have enough charge to turn over. Finally wised up and got one.