Charging system problem solved - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 6 (permalink) Old 10-05-2013, 04:44 PM Thread Starter
wicker san antonio
 
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Charging system problem solved

My 2002 w 26000 miles would leave me stranded. Took it to a reputable mechanic who could not pinpoint the problem. Sometimes he would get a bad reading from the regulator and sometimes the fuse box and sometimes the stator. Not wanting to just throw parts at the problem, he told me he could not determine the exact problem. Thanks to a neighbor's help we did a systematic diagnosis. It first appeared the RR was the problem. With a new RR it was better but after running 30 minutes the battery was down. We then pulled the fuse box and carefully took it apart( a sealed component not designed for repair), examined it , tested it and then glued it back together.
Recharged the battery and checked the voltage output from the stator wires while the bike was running and one leg was very low. So I bit the bullet and ordered a rebuilt from Tim Parrot Enterprises. Got it installed bout a week ago and my problem is solved.
In summary if u suspect your stator, check the voltage while the bike is running at each of the three yellow wires coming from the stator to the voltage
regulator to make sure u get the proper reading.

Use the "tilt and slide " motor relocation. It is not rocket science. After u remove all the ancillary stuff, and u are ready to remove the engine mounting bolts,,,,GO SLOW and follow the ARCHIVE engine pull...index.phpt/t-6532.html Instructions by Doowriter and Dianna.
This procedure can be done by one person, but is much easier with a helper, other wise when u get the 3 engine bolts out u will need to move from one side of the bike to the other as u examine the progress in moving the engine a determine where u need to apply the pry bar to get the motor free from the mounting bolt brackets. The motor needs a little coaxing to get it to clear the brackets...and once clear of these brackets..comes the ah ha moment when the motor easily slides over the 1 and 1/2inch u need to remove the stator cover.
The key to eliminate frustration is to GO SLOW and analyze each step first. If u experience a hang up with the motor, slowly and methodically exam which mounting bracket( or other part) is holding u up. This may require several trips up and down from the floor and around the bike. Be patient! Then carefully pry the motor away from the bracket. Choose ur pry points carefully so as not to punch a hole in the engine case.
I recommend the Hondabond HT silicone gasket seal. I did not use a factory gasket or any gasket, just the hondabond.

Good luck.
Wicker San antonio

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post #2 of 6 (permalink) Old 10-05-2013, 06:53 PM
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Nice job! I've done it with the carbs still attached. Just takes patience.

"Show me a man who makes no mistakes, and I'll show you a man who doesn't do things." Theodore Roosevelt."

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post #3 of 6 (permalink) Old 10-06-2013, 02:04 PM
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I just pulled the engine when my stator was bad start to finish it took me 4 hours to swap the stator

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i got my helmet but it sure makes licking the windows a chore

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post #4 of 6 (permalink) Old 10-07-2013, 04:17 AM
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glad to know it worked out good for you.. What R/R did you through in there?
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post #5 of 6 (permalink) Old 10-07-2013, 12:55 PM
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So the stator just went bad? Was your R/R relocated? De-goat? Pick-up coil mod?

I'm trying to see what preventive maintenance I can do to ease the work load on the charging system so the stator would not go bad on me. Or is that pretty much an eminent doom that we all have to face?
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post #6 of 6 (permalink) Old 10-07-2013, 04:17 PM
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Quote:
Originally Posted by vinhtvu2 View Post
So the stator just went bad? Was your R/R relocated? De-goat? Pick-up coil mod?

I'm trying to see what preventive maintenance I can do to ease the work load on the charging system so the stator would not go bad on me. Or is that pretty much an eminent doom that we all have to face?
Keep your oil level full, that will help. I think my 94 had the original stator and I sold that with around 24,000 miles on it.

"Show me a man who makes no mistakes, and I'll show you a man who doesn't do things." Theodore Roosevelt."

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