MIGHT have to cut stator wires... Please advise - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 22 (permalink) Old 08-20-2019, 10:23 AM Thread Starter
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MIGHT have to cut stator wires... Please advise

Hi guys. Just picked up my 750 this week. It's also my first bike!! Love how it rides. I got it for an absolute steal, so its got higher miles and a few issues. I'll get to the point now...

Previous owner, or the one before him, thought it would be a great idea to put a massive glob of JB weld right over where the stator wiring comes out of the housing (to try to stop a leak)...
I'd like to remove the crap, and get in there and see if I can just replace the grommet and fix the thing properly...

However, we all know JB weld can be a nightmare to remove... And i may end up having to just resort to the angle grinder. If I do, I don't think I'll be able to be delicate enough to save the wires...

If I happen to cut straight through all three wires (I think there are three correct?) will I be able to simply repair them? I'm not an electrical guy so I guess I'd want to know what I'm getting myself into at that point. Could I just shave back some of the rubber, and use a clamp/crimp connector on them and wrap them back up with electrical tape? or would that cause currency/voltage issues?

If I have to replace the entire assembly, then I think I'm screwed, right? because the stator needs to have the motor pulled to gain access to it? unless they did the "mod" to it... I am not looking for that kind of project right now. The bike runs really well, and the oil leak is very minor.

Any advise would be very much appreciated! I will try to post up some pictures of this mess, but suffice it to say they used a LOT of epoxy...

Last edited by Dokuji; 08-20-2019 at 10:52 AM.
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post #2 of 22 (permalink) Old 08-20-2019, 11:03 AM
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Oh man I don’t think I’d go that route, electrically speaking any additional “connections” you make can increase resistance and heat across the leads. And like you stated if you cut them and short them out anyway, you’ll screw yourself.
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post #3 of 22 (permalink) Old 08-20-2019, 11:06 AM
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If it were me, I'd just live with the leak if it's small.

If you damage the stator wires, it would be POSSIBLE to splice the wires inside the case and bring the new tails out through the new grommet, but then you've got a home-made splice in a harsh environment (out of sight, inside a case with hot oil). I would avoid that if at all possible.

If you decide you absolutely must attack the JB weld, I'd try to chisel out the wires first, then use heat on the JB left stuck to the case and scrape it off instead of grind, so you don't damage the case (making the new grommet not fit tight at the end of the day)

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post #4 of 22 (permalink) Old 08-20-2019, 11:21 AM Thread Starter
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Quote:
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any additional “connections” you make can increase resistance and heat across the leads. .
ok, then i definitely don't want to do that. My understanding is that overheating is what causes these stator coils to fail so frequently in the first place. thanks for the advice
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post #5 of 22 (permalink) Old 08-20-2019, 11:23 AM Thread Starter
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If it were me, I'd just live with the leak if it's small.

If you damage the stator wires, it would be POSSIBLE to splice the wires inside the case and bring the new tails out through the new grommet, but then you've got a home-made splice in a harsh environment (out of sight, inside a case with hot oil). I would avoid that if at all possible.

If you decide you absolutely must attack the JB weld, I'd try to chisel out the wires first, then use heat on the JB left stuck to the case and scrape it off instead of grind, so you don't damage the case (making the new grommet not fit tight at the end of the day)

I suppose I can live with it, but its not a good look leaking a few drops of oil anywhere I stop lol. I've been keeping an eye on the oil level since I got it and it really is very minor... part of the reason I want to clean it up though is to make sure there isn't another source/leak somewhere else. Thanks for the reply!
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post #6 of 22 (permalink) Old 08-20-2019, 11:51 AM
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Quote:
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Quote:
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any additional “connections” you make can increase resistance and heat across the leads. .
ok, then i definitely don't want to do that. My understanding is that overheating is what causes these stator coils to fail so frequently in the first place. [IMG class=inlineimg]/forum/images/smilies/icon_sad.gif[/IMG] thanks for the advice
No problem, my stator crapped a few months ago, one of the factory bullet connectors was so corroded, I’m sure that was probably a contributing factor to its failure. But like Thorn said if the leak is really minor just deal with it before you cause yourself more headaches.
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post #7 of 22 (permalink) Old 08-20-2019, 11:58 AM Thread Starter
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When you replace the coil assembly that comes with wiring, where does that connect, inside or outside the housing? Maybe one day ill order that part (can be found for like 50$) and tackle the stator mod project and that might be the best way to take care of this? that way i can chop the old one out without worry. unless the connection is made inside the housing, but that wouldn't make sense to me? it's gotta be outside correct?

edit: referring to this part

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post #8 of 22 (permalink) Old 08-20-2019, 12:01 PM Thread Starter
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actually i can answer my own dumb question because i see the grommet right there meaning the "bullet connectors" you refer to are indeed outside. so yeah, i think thats what I'm going to have to do.

If I take the cover off just to peek inside will i have to order a new gasket?
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post #9 of 22 (permalink) Old 08-20-2019, 01:56 PM
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Quote:
Originally Posted by Dokuji View Post
actually i can answer my own dumb question because i see the grommet right there meaning the "bullet connectors" you refer to are indeed outside. so yeah, i think thats what I'm going to have to do.

If I take the cover off just to peek inside will i have to order a new gasket?
There’s the plate on the left side of the motor that you can “peek” in from, I’m not sure that has a gasket. The stator cover itself is what can’t be removed without tilting or removing the engine. The stator plate mod can be done but for me personally I would never cut the plate while still on the bike. You’re asking for metal shavings or debris to get into the engine. Those 3 wire leads you see coming out are directly connected to the windings in the stator. I think the company is TOC that sells the modified plate kit but it’s about $400.
I’m not sure I’m following but why do the mod of the bikes charging system is working? I thought the issue was more cosmetic with the JB weld
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post #10 of 22 (permalink) Old 08-20-2019, 02:14 PM
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Quote:
Originally Posted by Dokuji View Post
actually i can answer my own dumb question because i see the grommet right there meaning the "bullet connectors" you refer to are indeed outside. so yeah, i think thats what I'm going to have to do.

If I take the cover off just to peek inside will i have to order a new gasket?
There’s the plate on the left side of the motor that you can “peek” in from, I’m not sure that has a gasket. The stator cover itself is what can’t be removed without tilting or removing the engine. The stator plate mod can be done but for me personally I would never cut the plate while still on the bike. You’re asking for metal shavings or debris to get into the engine. Those 3 wire leads you see coming out are directly connected to the windings in the stator. I think the company is TOC that sells the modified plate kit but it’s about $400.
I’m not sure I’m following but why do the mod of the bikes charging system is working? I thought the issue was more cosmetic with the JB weld
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