First off, thanks for all the informational reading I've been doing the last few days. I think I may need to replace the stator in my 94 vn750. Pretty sure the R/R is gone. Before I get too far into this repair I'd like to know if a discharging battery would cause the bike to overheat on a 98 degree day. I'm sure about the temperature because I got to look at the bank sign for three hours waiting for my buddy with a trailer! My thought is that the low voltage may have contributed to the overheating. When the battery was fresh from its overnight tender charge the operating temperature was high but in the normal range. The cooling system is all new except for the impeller and I haven't had problems until the recent hot stretch.
Iíve noticed the bike running hotter lately. A few days ago I had problems starting but it got me home. I checked the old lead acid battery and it was dry. I refilled and charged it, but after some reading decided to replace it with the AGM battery from Advanced Auto. I relocated the R/R and left it on the charger overnight then went on a ride the next day. It ran great for 40 miles then started overheating and not running as well. It stalled at a stop light and was done. Luckily it started and ran long enough to drive it on the tilt trailer three hours later.
When I got it home the voltage was about 10.4. I charged it overnight to 12.5V. I started it and brought it up to temperature, then ran some of the tests in the Kawasaki manual. The R/R Output voltage was only 13V @ 4000RPM, 12V @ idle. I donít have a meter that can measure 20 amps DC in series so I skipped that test.
The stator coil resistance between leads is 2.2, 1.3, and 1.3 ohms (corrected for lead resistance). They call for .34 to .52 but that seems like a tight range for a set of windings to me. The stator coil insulation test showed infinity from ground to all the leads. I don't want to change this beast if I don't need to. Would much rather be riding.
Testing on the R/R was interesting. The harness connector has been very hot; it is burnt and brittle. The R/R connection looks similar. The B pin has 1.6 ohms to A1, A2, and A3 where it should be infinity. Actually, the only readings that look good are the A1/A2/A3 to each other. Figure its junk.
In a nutshell:
1. Do I have a separate cooling issue? This system was cleaned and flushed a few months ago. Radiator serviced at a shop, all new rubber, no leaks, and new thermostat. It has been running OK till recently.
2. Do I replace the stator or do some more testing? Replacing looks like a PITA. Should I test the AC output? And if the stator is marginal can I install a new R/R and get by until winter?
3. Which R/R to install? My harness side plug is burnt but usable. I like the simple concept of the MOSFET type. The ElectroSport unit gets good reviews and is much cheaper than the OEM one. Whatever I get may have to live with a marginal stator for a while.
Thanks in advance for your support. I don't mind getting my hands dirty but when you're up to your neck with alligators.... This is a 94 VN750 with 39000 miles.
you need to do one more test on your stator ,if i didn't miss anything.
Set your meter to ac voltage probably 200 V scale,and test for voltage across all combinations of stator output leads,you should get a reading of 40 to 70 VAC between any and all combinations ie:AI to A2,A1 to A3 and A2 to A3 with the engine running 2500rpm or better.If in spec on all combos your stator is good ,also after doing this test retest for any lead grounded to the engine case with the engine warm.
If you have to but an R/R ,go for the mosfet kit ,I personally believe it is the single best charging upgrade you can do and is worth waiting for another payday or two to buy if you have to, I hope this helps.
On the overheating issue i would wait till the bike is running at full voltage,before I passed judgement on the temp gauge.It works of of a resistor type sending unit and voltage and resistance variances on either of the two could cause false readings,
If you see it on my bike I did it
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