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Discussion Starter · #1 ·
Hello,
Guys....have about 22k miles on my 2004 750 and replaced my stator last year with OEM kawasaki stator and have relocated the original oem regulator to the back where it's getting cooler air. I also installed a voltmeter on the bike after my stator failed to monitor the voltage. Bike has been running fine with no issues, charging voltage output in 14.5-14.6. on the battery side while revving the bike to 3000-4000 RPM

I was inspecting all my wirings and hoses last week while the bike was running and noticed my 3 yellow stator wires were too hot to touch. So, I'm simply asking if they are normally suppose to get hot like this? I do not have them bundled or wrapped together, the 3 little bullet connectors are clean and tightly inserted and have about 3- 4 inches air clearance in between them.

Thanks in advance for any and all feedback!
 

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Discussion Starter · #3 ·
Thanks for the reply....well, looking at the yellow wire bullet connectors, they are the original OEM from kawasaki and they connect to stator wires coming from Stator. I have not traced these wires to see how they connect to the R/R, but I have inspected the plug and the wires that connect to the OEM kawasaki R/R , both the wires and plug looks good and does not have any sign of burning or discoloration. Although the 3 yellow stator wires get very hot to touch, I didn't see any melting or burning sign, just hot to touch!

Not sure what to think!!
 

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Discussion Starter · #5 ·
They are actually too hot to touch! I just looked at the 3 yellow wire connections coming from the new stator and they are thick and very flexible. However the 3 yellow wire connections coming down from under the seat to connect to them, have gotten thin and they are quiet stiff about an inch before they bullet connect. I wonder if that small stiff wire sections mean the wires has been damaged or burned? it still has the yellow plastic jacket on them but they are very stiff about an inch on each of the wires. If I need to replace the 3 wires coming down from under the seat , are these special wires or what gauge wire should I use?

Thanks again guys!
 

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Discussion Starter · #7 ·
Thanks Spockster...I have an Ohm meter and Clymer manual and I'm getting 14.6 voltage to make sure it's charging. The Stator is OEM from Kawasaki dealer and it has less than 1000 miles on it...How is the best way to Ohm test it? I'm thinking i should follow the 3 yellow wires coming down from under the seat that connect to the stator bullet connections to make sure they are not damaged.

I appreciate any other thoughts or ideas!
 

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Discussion Starter · #9 ·
Ok...I will look through the charging system page for the ohm test resistance across the 3 leads of the stator. But can you please tell me about the continuity tests with 3 wires unhooked.. looking at my R/R plug, it looks like I have 6 wires going to this plug. 3 yellow wires at the bottom (which I assume are the same wires that connect to the stator ? ) and 3 wires at the top section of the plug (brown -white-yellow&blk) . With bike off, I should be testing the continuity of the 3 yellow wires from the bullet connection to the R/R plug to make sure there's no disconnect or problem, right?
 

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Discussion Starter · #11 ·
Well guys....per Clymer manual I just checked the resistance between each yellow wire on the stator side and I have (Zero - 0) on my multimeter indicating full continuity. Then I tested each yellow terminal to ground and I get (One- 1) on the multimeter indicating No continuity. I also checked resistance & continuity from the 3 yellow bullet connectors to the R/R plug and I also have (zero-0) resistance and full continuity. I did touch my regulator and it is very hot as well but the plastic plug looks ok and no burning or dirty or rusty spots, so I'm not sure if it's the entire yellow wiring that may just be getting hot or should I take the seat off and trace the 3 yellow wires from the stator to see if I see anything obvious!

Any ideas or suggestions, as to what I can try next would be great.....Thanks again everyone!!!
 

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Discussion Starter · #13 ·
Sorry....I just tested again and on my multimeter in the Resistance section I only have 20 - 2000K - 200k I put on just 200 . When I put on 200 , I get 00.9 resistance in between the 3 yellow terminals.
 

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Discussion Starter · #19 ·
The battery is new , I just bought it last month from Batteries Plus, it's Duracell closed cell sealed battery and 210 cca. I think I'm going to cut the 3 piece of yellow wire by the bullets that is rock hard and not flexiable at all and just replace it with 6 inch of good 12 gauge or maybe 14 gauge wires and either solder the wires or use crimp connectors and see if that is my problem. I am working night shift this week , so it will be next weekend.

12 gauge or 14 gauge should be heat tolerant, right? will try it and post results!

You guys are awesome...many thanks!
 

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Discussion Starter · #27 ·
Guys....Happy to report that once I replaced about 6 inches of the 3 yellow wires that was bullet connected to the stator, the "Hot to the touch" wire issue has been resolved! I could not find High temperature 12 gauge wire, but found High temp 14 gauge wire (+200 degree Fahrenheit) and replaced the stiff -not bendable yellow wires that connected to stator. Had the bike at idle till it reached normal operating temperature and wires were just a barely warm to touch.

Once weather starts to cool off a bit , going to do the Pickup coil mod and reduce the gap to 0.20 . I have been dealing with hot start, backfire issue at gas stations and short stops ever since I owned the bike, even with top of the line sealed battery, irradium spark plugs. Many...Many thanks to all of you for all the help on this forum......you guys are Awesome!!!
 

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Discussion Starter · #30 ·
Guys....I just finished the pick up coil mod Saturday morning on my Vulcan 750. Oh....My God..... What a difference!!!! The bike starts Hot and cold with just a push of a button! I followed the directions and set the gap to 0.020 and used the dremel tool to shave just a little off the pick up coil bracket and elongated the screw holes. I have not taken the bike out for a long ride, but just trying in my garage , I can tell the difference of how quickly the bike starts!! weather was rainy...so I'll ride it next few days to make sure.

Thanks again for the help & sharing the knowledge.....hope this info helps the next person!
 
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