Goof Proof Stator Test! - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
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post #1 of 19 (permalink) Old 09-09-2008, 09:01 PM Thread Starter
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Talking Goof Proof Stator Test!

I unfortunatly found this & understood "Exactly" what & how to test. I did follow the step by step diagnosis page repeatedly supplied here but I didn't think I was performing the tests right. How can I screw them up? It's easy! Any way here is what I found to help me. To bad the photo's where expired. But the write up works.

First off the Reg/Rect can when it goes bad Overcharge/Undercharge or not charge the Battery at all depending on what goes wrong with it

So to check the Stator is working ok..

Locate the 3 wires that come out of the Generator cover that are all the same color and follow them to the Plug, Disconnect at this plug because this is where you'll preform your testing...

Bike is a ZX6R J2 for Illustration only....And you can see the 3 Black wires centre of picture....Your looking for similar, I think the wires may be "YELLOW" on your Bike.




Here is the Plug disconnected and the end that is attached to the wires from the Stator is the one to test at.


Yours will probably look more like this white one from a ZX10R..With the 3 wires all inline, Same deal though



First test is to see if any of the 3 Phases have shorted to Ground.Ignition OFF.Connect Your Multi Meter as follows:-
Black Lead (Ground) to Battery Neg Post. See Picture..


Red Lead (Positive) to any ONE of the 3 Connections in the Plug..See Picture.


And you should get O Continuity showing on the meter or O.L as mine is showing set to the OHMS scale in the Picture below.
Repeat this on the remaining 2 connections and if your meter gives you a reading other than no continuity there's a problem right there because you have a Phase gone to ground....BAD


If they all check out ok then the next test is a Resistance check again on each Phase but this time with each other..
Leave your meter set to OHMS Scale.

To assist with the tests lets Number the 3 Connections 1,2 & 3it will make it easier to follow..

Ok connect the leads as follows i've done the first one in the Picture..

1~ RED LEAD
2~ BLACK LEAD

1~ RED LEAD
3~ BLACK LEAD

2~ RED LEAD
3~ BLACK LEAD

Take a reading for the 3 tests above and they should be between .3 and .6 OHMS for each of the 3 tests...Don't worry to much if there a touch under or over as i have only given an average as long as you get somewhere near there ok.




I have included a picture below of the reading i got when i measured the connections in the picture above..



Ok last test on the Stator is the same as the one you've just done but this time the Meter must be set to 100 VOLTS AC or more if your meter is incremented differently to mine, As long as it's around 100 your ok. .

On my meter in the Picture above i would have it set to A~ Because it is Auto Ranging it has no Values that i need to set it to, Yours may have A~ then probably 2 different AC Voltage ranges

At this point you need to be able to run your motor as this tests the output from the stator coil across the 3 Phases.Please make sure you can do this safely and still carry out your tests, Because there will be anywhere between 40 and 80 volts AC at that Plug your gonna be testing at so no PETROL slopping about whilst your touching the probes from the meter onto the connections as there can be small SPARKS when your making the connections.........

You set fire to your bike and i'm Gonna say i told you so....Please be carefull..

OK Fire Suit on ??? Lets play

1~ RED LEAD
2~ BLACK LEAD

1~ RED LEAD
3~ BLACK LEAD

2~ RED LEAD
3~ BLACK LEAD

Start the motor, Increase the revs to about 4k and take a reading for the 3 above....I find it easier to get an assistant to hold the revs and record the 3 sets of readings whilst i am making the connections.

Your looking for anywhere between 40 and 80 Volts AC the main thing is the 3 readings from the 3 Phases of the stator are all somewhere near the same as each other..

At this point if all the testing comes out GOOD i would suspect the REG/RECT has seen better days and replace it...



So with mine testing out at .8 ohms & 1 lead making about 5v opposed to the 40-80v suggested (per bike I suppose). The other 2 are making roughly 45v. So as best as I can tell I've got a dying not dead stator. Right!? Ah, what fun lies ahead.
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post #2 of 19 (permalink) Old 09-09-2008, 09:12 PM
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You are right on for how you explained how to completely test out the stator. Nice write up, to bad the pictures did not come up. Thanks from all of us.

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post #3 of 19 (permalink) Old 09-09-2008, 09:19 PM Thread Starter
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I didn't write it I just found it!
Question! Is it normal for a stator in this state to sometimes charge & sometimes not? I'm seeing this symptom. I know it's bad & needs replaced but I'm curious about this. Thanks all!
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post #4 of 19 (permalink) Old 09-09-2008, 10:46 PM
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Quote:
Originally Posted by kanuck69 View Post
I didn't write it I just found it!
Question! Is it normal for a stator in this state to sometimes charge & sometimes not? I'm seeing this symptom. I know it's bad & needs replaced but I'm curious about this. Thanks all!
There have been several reports of the stator working fine until the engine got hot..then the stator craps out. Stop the bike and let it cool off...and then the stator seems to be working fine again.

My thinking here is the primary reason the stator goes bad is because it looses insulation off the wire winding somewhere. So it does seem possible that as metal expands with heat, the area of broken insulation expands into something it is grounding out on...couple this with the oil coating thinning when hot and it suddenly seems plausable that the stator output could become rather sporadic.

If You Are Not Sure If I Am Joking or Not....I AM !!Photos:
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post #5 of 19 (permalink) Old 09-12-2008, 08:35 PM
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I took a reading on the 3 yellow wires to ground. I had the meter set to 2000ohms scale. Got a reading of 002 on all 3 wires. Is this a good reading or bad? I am not to good on the meter thing on reading results. When I put the red and black leads together this was the same reading 002
Then did the test of 2 wires wires together. Got a reading of 1.2 on all 3. this was on the 200 ohms scale this time. If I read the test correct. I am getting a bad reading?
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post #6 of 19 (permalink) Old 09-12-2008, 09:56 PM
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Quote:
Originally Posted by tprender View Post
I took a reading on the 3 yellow wires to ground. I had the meter set to 2000ohms scale. Got a reading of 002 on all 3 wires. Is this a good reading or bad? I am not to good on the meter thing on reading results. When I put the red and black leads together this was the same reading 002
Then did the test of 2 wires wires together. Got a reading of 1.2 on all 3. this was on the 200 ohms scale this time. If I read the test correct. I am getting a bad reading?
Both your readings are in the good range. But don't get your hopes up yet, you still need to get your AC Volt reading from the three yellow wires coming off the stator while the engine is running and at different RPM's. The standard is at idle (1k rpm) and at 3k and last at 5k. Get those readings next and that aught to tell you if your stator is good or bad.

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post #7 of 19 (permalink) Old 09-13-2008, 08:49 AM
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I was guessing that the stator was bad, becasue when I get the bike running my volt melter only reads 12v at all speeds. I have another r/r and when I put it on. I still get 12v. At the beginning of the week it was reading 14v running. I guess that both of my r/r are bad then. I have tried to test them, and not sure about the reading on them yet. Will go and have them checked out by someone today who knows what they are doing.
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post #8 of 19 (permalink) Old 09-13-2008, 09:45 AM
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Are you testing the yellow wires that are coming from the stator, not the battery but the stator wires? Do you have your meter set for AC voltage when your running these tests?

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post #9 of 19 (permalink) Old 09-13-2008, 03:11 PM
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Pictures in Gallery of additional oilcooling of stator

Quote:
Originally Posted by Knifemaker View Post
There have been several reports of the stator working fine until the engine got hot..then the stator craps out. Stop the bike and let it cool off...and then the stator seems to be working fine again.

My thinking here is the primary reason the stator goes bad is because it looses insulation off the wire winding somewhere. So it does seem possible that as metal expands with heat, the area of broken insulation expands into something it is grounding out on...couple this with the oil coating thinning when hot and it suddenly seems plausable that the stator output could become rather sporadic.


With regards to KN`s highlighted statement above, there are some pics in the gallery of a mod where a couple of oil lines were plumbed into the alternator case to provide additional cooling to the stator. (I`ve tried looking and using the search there, but have not been able to locate the pics again that I know were there a week or so ago.) Can anyone tell me how to find it again and /or who built it? Also do you know how this mod worked out?

Question to KM or any others with insight on this mod; does this sound like a practical, effective and cost efficient way to help keep our stators from premature failure? If the engine has to be pulled for stator replacement or any other reason anyway, one who has the inclination and skills required, could try this to prevent a future failure.

Don`t want to hijack thread. It just seems like every second thread on here has to do with charging system.

Gordon

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TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #10 of 19 (permalink) Old 10-08-2011, 02:32 AM
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Quote:
Originally Posted by OlHossCanada View Post
[/B]

With regards to KN`s highlighted statement above, there are some pics in the gallery of a mod where a couple of oil lines were plumbed into the alternator case to provide additional cooling to the stator. (I`ve tried looking and using the search there, but have not been able to locate the pics again that I know were there a week or so ago.) Can anyone tell me how to find it again and /or who built it? Also do you know how this mod worked out?

Question to KM or any others with insight on this mod; does this sound like a practical, effective and cost efficient way to help keep our stators from premature failure? If the engine has to be pulled for stator replacement or any other reason anyway, one who has the inclination and skills required, could try this to prevent a future failure.

Don`t want to hijack thread. It just seems like every second thread on here has to do with charging system.

That was a really cool mod by darrelc5:

https://www.vn750.com/forum/showthrea...ghlight=tubing

http://www.flickr.com/photos/2339973...7605602927618/
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