yellow stator wires - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 7 (permalink) Old 05-24-2010, 10:24 PM Thread Starter
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yellow stator wires

Noticed the other day after sitting at idle for 10 min, the three yellow wires from the stator were smoking & hot to touch. Any idea what this indicates? Too close to the exhaust or something much worse?? Bike is an '03 with 900 miles.
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post #2 of 7 (permalink) Old 05-24-2010, 10:34 PM
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my wires burned all the way thru about 9 months ago.(pics in my profile) had to solder in new wire. several people on this site who are smarter then me said it was rusty or oxidized connectors on the stator wires. look for the three plug type connectors on those wires and clean them. there is a procedure for testing your stator in the book and i think its on this site somewhere.

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post #3 of 7 (permalink) Old 05-24-2010, 11:28 PM
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the stator test is all over the sight.. i know I have posted a full write up on it several times... even made it prety much dummy proof. as for the reason of the wires in question burning... several things it could be... stator shorted to ground, bad connections, bare wires, stator wire leads shorting to ground at the stator housing, and a bad regulator/rectifier can all lead to the cause of your wire issue. ohh one other thing... a bad ground
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post #4 of 7 (permalink) Old 05-25-2010, 02:27 AM
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My wires got hot too - cause? corroded connectors. I cleaned and used dielectric grease on them and no problems x7 years. Time to check them again...


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post #5 of 7 (permalink) Old 05-25-2010, 05:02 AM
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My wires also overheated, on both sides of the bullet connectors. The insulation hardened, and one of the connectors simply broke off. I removed the connectors, and soldered the wires together. I have checked them several times after that, and can find no signs of overheating. My theory is that poor contact at the bullet connectors caused very high resistance, which is what overheated the wires. They were nowhere near any other source of heat. Jerry.

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post #6 of 7 (permalink) Old 05-25-2010, 08:09 AM Thread Starter
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Thanks for the input, guys. I checked the stator out per Clymers manual- OK. Gonna use some dielectric grease and quit worrying so much!
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post #7 of 7 (permalink) Old 05-25-2010, 10:10 AM
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Yep, more than likely corrosion in the bullet connectors causing resistance. Best thing is to trim back to good wire and solder in/heat shrink new wire and toss the connectors. Also, don't bundle all three wires together, but leave them separated. This will keep them from heating on each other.

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