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Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
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post #21 of 32 (permalink) Old 03-13-2020, 12:45 PM
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Or the guy noticed it was rubbing, and hammered in the lowest bolt hole a bit to raise the clearance, but it wasn't enough?

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post #22 of 32 (permalink) Old 03-13-2020, 12:55 PM
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So the legs of the stator shouldn't be electrified, only the windings, so even if it were rubbing (obviously that's still bad) it wouldn't be shorting. That loose wire has to be a piece of the winding, and is likely the source of any shorting (well, the OTHER end of that break is probably what is shorting).

A new stator and a new plate should fix the problem. And possibly a new R/R. a scuffed rotor shouldn't be a big issue.
Um, is the rotor scuffed on just that one side, or is it all the way around?

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post #23 of 32 (permalink) Old 03-13-2020, 03:23 PM
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Looking at this pic, the mod plate looks severely tilted to the left, and most of the right side is gapped away from modded stator mount (the cutout piece).

Is this only due to the plate being warped, or is there anything wrong with the screws? Are the screws all bottomed out against the 'case' and tight? I would blue Loctite all the screws for this mod, stator mount and mod plate scews.

Also see a loop of the coil winding sticking up kinda close to the iron.. Is it touching there?

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post #24 of 32 (permalink) Old 03-13-2020, 06:10 PM Thread Starter
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I took some More photos to help show what Ive found. from what I can see I’m 100% sure that what Is sticking up on the stator, is actually part of the stator leg... it appears to have delaminated and started to come apart. And the leg next to it was about to go as well..the rotor does have scratches all the way around but mainly just that half of it.. as for the mounting plate. the tilt was partly to do with my picture but it is definitely not flat. It looks to me like the P.O over tightened the screws, causing the plate to bend around the small tabs/veins on The case. Unfortunately either way I think I will have to pull the motor because I got impatient and broke par of the generator cover.
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post #25 of 32 (permalink) Old 03-14-2020, 01:33 AM
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Wow.

1992 US-nonCA * tuxedo mod * r/r relocated

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post #26 of 32 (permalink) Old 03-14-2020, 01:44 AM
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WOW is right, the P.O definitely did not do this right... and that stator plate is likely ruined unless you can get it straightened perfectly.
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post #27 of 32 (permalink) Old 03-14-2020, 10:33 AM
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These bikes won't shift above,2nd gear unless they are running

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post #28 of 32 (permalink) Old 03-14-2020, 04:09 PM Thread Starter
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Quote:
Originally Posted by OleDirtyDoc View Post
These bikes won't shift above,2nd gear unless they are running

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realy? Beacuse that would make me feel better lol I’ve never heard that before. Never had a bike I couldn’t shift through all the gears by rocking either. Any others have. Experience with this?
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post #29 of 32 (permalink) Old 03-14-2020, 06:14 PM
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realy? Beacuse that would make me feel better lol Iíve never heard that before. Never had a bike I couldnít shift through all the gears by rocking either. Any others have. Experience with this?
Yep, won't shift above 1st unless it's moving about 10 mph, maybe a little slower. Most if not all Kawis have the PNF, Positive Neutral Finder. So if you're stopped, it will only go into neutral or first. You can get neutral without doing a half shift.

Makes it kind of a bear to push start. Have to let the clutch out in first, then if you have helpers pushing, you might be able to get 2nd if it didn't start right away.

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post #30 of 32 (permalink) Old 03-16-2020, 11:57 AM Thread Starter
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Well I’ve decided to keep at it...I spent most of the day yesterday and a few minutes this morning🤦‍♂️ pulling the engine. What a chore ....anyways. I’m going to clean it up and order a replacement generator cover. And I plan on doing the stator mod to the new cover, Properly. Should I cut out the new cover for the stator and pickup wires or rout them through the original opening. Also who makes the best stator plate kit. if i cant get this one back to flat.
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