Stator Burn-out Solved? - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 34 (permalink) Old 01-25-2007, 03:36 PM Thread Starter
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Stator Burn-out Solved?

I replaced my stator for the second time recently and while I had the engine open, I added an oil tube to douse the stator with engine oil. Hopefully, this will actively cool the stator and keep it from burning out. I live in Tucson and commute on the freeway and when the traffic backs up, the engine gets pretty damn hot.

I haven't actually driven the bike yet, but I warmed the engine up and removed the timing inspection cover and observed copious amounts of oil splashing about. In fact, the first time I started it with the cover off, I had to immediately shut it off and fabricate a splash screen to catch the oil being driven out from crankcase blow-by. There's a lot of churn going on around the flywheel, given that the timing chains are right behind it. I could see a solid stream of engine oil coming from the two oil tubes that I added, spraying the back of the stator. Oil also shoots past the stator and floods the cavity between the stator and flywheel.

Before I started the engine for the first time, I connected an oil pressure gauge. At idle the engine has 50 psi and at 4000 RPM it has about 70 psi of oil pressure, so there doesn't seem to be any pressure loss due to redirecting some for cooling the stator.


01/31/07, Update - Photos of the stator cooling mod: Yahoo Photo Album: Vulcan Oil-Cooled Stator Mod

Darrel
'03 Vulcan 750 (90k miles)
-Corbin Seat
-V-Force Windshield
-LeatherLyke Touring Bags
-Chrome Luggage Rack
-Headlight Modulator
-Brakelight Flasher
-MF Battery
-Heads-Up Voltage Monitor
-Replaced Stator (9,000 and 16,000 mi.)
-Oil-cooled Stator Mod (photos)
-Replaced and Relocated R/R
-Greased rear splines
-Fused Stator (photos)
-Metzeler ME880 Marathon 170/80-15 (Rear), 110/90-19 (Front)
-TOC MCCTs installed
-Headlight Relays
SOLD - 2013

Last edited by darrelc5; 02-12-2007 at 02:14 PM. Reason: Add photo link
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post #2 of 34 (permalink) Old 01-25-2007, 05:07 PM
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Sounds cool. Let us know how it goes.

Fergy
Kyle, TX VN750.com member #707 VROC#19556
2002 VN1500 Classic
Spline Lube Procedure, with photos, R/R Relocation and Coil Mod
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post #3 of 34 (permalink) Old 01-25-2007, 05:19 PM
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yeah let us know! several of us are on a quest to lessen the stator issue... due to the nature of our charging system, it will burn out.... the question is when. when summer rolls back around i plan to take temp readings of the oil in the stator/flywheel area. i have a theory that there isnt very good heat tranfer from the engine to the water cooling system....leaving alot of heat in the oil... i've already come to the conclusion that the wires that they were using before must have been polyester coated. great chem resistance, but heat is about 275 degs far before it starts to suffer.... and well on a hot day i have a feeling our oil is poking around the 250 mark, and heaven forbid you hit traffic. keep end mind that the stator produces its own heat too, so cooling it with 250 deg oil may not be doing much cooling.....but like i said, its my theory.... i will better know this upcomming summer.

plus then i will get to beat up my frankenstator....

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
Givi hard bags w/ custom rear turn signals


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post #4 of 34 (permalink) Old 01-30-2007, 05:01 PM
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So Darrell, don't hold out on us! Been riding any?

Fergy
Kyle, TX VN750.com member #707 VROC#19556
2002 VN1500 Classic
Spline Lube Procedure, with photos, R/R Relocation and Coil Mod
Rusty Tank Cleaning!
Electrical Fault Finding Flowchart
SEAFOAM JUNKIE!


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post #5 of 34 (permalink) Old 01-30-2007, 07:11 PM
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just curious where did u plug up the oil pressure gauge at... when i convert my gagues to digital, i want to monitor that. is it in a rideable location, or just temparary?

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
Givi hard bags w/ custom rear turn signals


Band Engineer/Webmaster for Josey Contreras Tejano Band
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post #6 of 34 (permalink) Old 01-31-2007, 10:23 AM Thread Starter
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Quote:
Originally Posted by Hizzo3 View Post
just curious where did u plug up the oil pressure gauge at... when i convert my gagues to digital, i want to monitor that. is it in a rideable location, or just temparary?
I used a shop oil pressure tester which screws into the hole beside the oil filter where the stock pressure switch is installed. When I started the engine for the first time, I wanted to make sure the bearings and lifters were getting sufficient oil.

If you have an aftermarket gauge set, that's where you'd want to plug the sensor in, or route the oil tube from. There's lots of space there.

Darrel
'03 Vulcan 750 (90k miles)
-Corbin Seat
-V-Force Windshield
-LeatherLyke Touring Bags
-Chrome Luggage Rack
-Headlight Modulator
-Brakelight Flasher
-MF Battery
-Heads-Up Voltage Monitor
-Replaced Stator (9,000 and 16,000 mi.)
-Oil-cooled Stator Mod (photos)
-Replaced and Relocated R/R
-Greased rear splines
-Fused Stator (photos)
-Metzeler ME880 Marathon 170/80-15 (Rear), 110/90-19 (Front)
-TOC MCCTs installed
-Headlight Relays
SOLD - 2013
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post #7 of 34 (permalink) Old 01-31-2007, 10:33 AM Thread Starter
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Okay! On Saturday I got the bike on the road and had a great little ride in the hills. Everything seems fine; no noise from the lifters and it runs just like it did before taking it apart. I heard a little popping in deceleration - probably from an exhaust leak. Haven't ridden since then due to rain and work schedule.

I posted a link to pictures of the work above in the original message.

Is there a way to tell if this mod is helping? If I get more than 8K miles before another ruined stator, then I'm happy. I plan to take the timing cover off every few months and inspect the stator coils for gummy oil residue. Both failed stators have had a lot of build-up.

Any thoughts?

Has anyone tested their oil pressure at 4K RPM? Mine is about 70 psi - well above the manual spec. I didn't test it before this mod, but it couldn't cause an increase. I was worried about a decrease, but I used 1/8" copper tubing and it doen't seem to be robbing an appreciable amount of oil volume.

Darrel
'03 Vulcan 750 (90k miles)
-Corbin Seat
-V-Force Windshield
-LeatherLyke Touring Bags
-Chrome Luggage Rack
-Headlight Modulator
-Brakelight Flasher
-MF Battery
-Heads-Up Voltage Monitor
-Replaced Stator (9,000 and 16,000 mi.)
-Oil-cooled Stator Mod (photos)
-Replaced and Relocated R/R
-Greased rear splines
-Fused Stator (photos)
-Metzeler ME880 Marathon 170/80-15 (Rear), 110/90-19 (Front)
-TOC MCCTs installed
-Headlight Relays
SOLD - 2013

Last edited by darrelc5; 01-31-2007 at 05:50 PM.
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post #8 of 34 (permalink) Old 01-31-2007, 03:19 PM
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it could cause an increase if it is restricting the oil flow, which may be possiable....if its more then 10-20% above spec then i would be worried, otherwise, you are fine... also keep in mind oil weight can cause difference in pressure as well as oil temp....

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
Givi hard bags w/ custom rear turn signals


Band Engineer/Webmaster for Josey Contreras Tejano Band
Hizzo3 is offline  
post #9 of 34 (permalink) Old 01-31-2007, 04:37 PM
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Hey, Darrelc5...

Just out of curiosity, what kind (petro-based, or synthetic) and what brand of oil are you using in your bike engine? And how often--in miles, and/or time--are you changing the oil?

Also: at what mileage (approx) did you relocate your r/r? When the stator failed the 2nd time--did it take the r/r with it?

Thanks!...
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post #10 of 34 (permalink) Old 01-31-2007, 06:13 PM Thread Starter
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I'm using the Shell Rotella T 15W-40 and I change it about every 5-6K miles.

The R/R was relocated when I replaced it at about 15K. I believe the first one is actually okay because I tested it incorrectly. With two different meters, I cannot get a continuity reading between the control line and the ground into the R/R. Oh well.

Darrel
'03 Vulcan 750 (90k miles)
-Corbin Seat
-V-Force Windshield
-LeatherLyke Touring Bags
-Chrome Luggage Rack
-Headlight Modulator
-Brakelight Flasher
-MF Battery
-Heads-Up Voltage Monitor
-Replaced Stator (9,000 and 16,000 mi.)
-Oil-cooled Stator Mod (photos)
-Replaced and Relocated R/R
-Greased rear splines
-Fused Stator (photos)
-Metzeler ME880 Marathon 170/80-15 (Rear), 110/90-19 (Front)
-TOC MCCTs installed
-Headlight Relays
SOLD - 2013
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