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Join Date: Apr 2006
3rd Stator Finally Right (I Hope)
Bought mine new in 04. Put 11,000 miles on it and had to replace the stator! Put an electrosport stator in it and had to replace it after another 10,000 or so. But that might be because I burned up an RR unit--who knows what caused what?
I replaced the RR, the junction box (it had some heat showing), the stator--all with Kawasaki replacement parts. Interestingly, the Kawasaki replacement stator was put together differently than the one that was on the bike when I bought it. The original one had the multistrand wiring clamped to the stator wiring--no solder and all three were stacked up on each other with insulation between them, and insulation sock around all of them. A perfect way to build heat. That is what heated--those joints, as seen on the stator windings where the insulation turned black just far enough back into the stator to short it. The rest of the windings were fine. But that much was all it took.
The Kawasaki replacement stator windings were clamped AND soldered so they did not create as much heat. And they were staggered so they did not add heat to each other. That is the way it should have been built to start with. And any bike that has a long-lasting stator probably has one like that.
I put new RR up in front, using heavy gauge wiring--one size larger than OE. I also put an oil cooler on the bike to keep the stator's coolant (engine oil) down to a reasonable temp.
I have close to 38,000 miles and seem to have a good system working now. Voltmeter shows a consistent voltage range for the past 2 years--all kinds of weather and riding.