Before you replace the stator check all your connections:
1. Battery nice clean no corrosion
2. The rectifier plug no burnt no corroded pins and clean and shiny
3. The stator connecter under the battery box make sure it's not melted and the contacts are clen.
below is a little more indepth procedure.
Specs:
Output: 14 Volts / 300 Watts / @ 5000 rpm
Stator Coil Resistance: 0.279 ~ 0.341 Ohm @ 68º F
Stator AC Voltage Output: 100+ VAC* @ 4000 rpm
Specs form a good system.
DC voltage up to 20V
AC Voltage up to 100+V
A fully charged battery should read 12.6 volts. If battery voltage is low charge it before testing the system, a weak or bad could cause false test results. Replace the battery if it will not come to a full charge from a battery charger.
start engine, turn off all electrical accessories measure charging voltage as rpm's are increased to 5000 rpm. Voltage should be 13.5 ~ 14.5 volts. Intermittent charging system problems could be caused by a bad connection.
If voltage is below 13.5 volts, it could be poor connections, bad wiring, faulty stator, and/or a faulty RR. Higher than 14.5 volts it's probably a bad RR and/or bad connection. Before digging into stator and rr check all connections, battery cables, RR connector, stator connector, solenoid connectors, and main fuse connection.
Stator Test
Engine and ignition off. Test at the RR connector, you get ot the RR connector by removing the two 10mm mounting bolts and lowering the RR. I had to remove the lower fairing to get to it disconnect the connector and inspect the terminal pins for tightness, corrosion, or damage.
Regulator/Rectifier location.
Check for battery voltage between connector terminals marked Bat+ and Gnd-.
Check the stator coil resistance by measuring at the three stator terminals of the connector. Set the meter to the lowest ohms scale and measure between pins 1~2, then pins 1~3, and finally between pins 2~3. All readings should be around .3 ohms. Some meters may not read accurately at this setting so don’t be too worried if you don’t get exactly .3 ohms. Next, set the meter to a higher ohms scale (>100 ohms), connect one meter lead to a good engine ground and use the other lead to test each stator terminal for a short to ground. All should read open (OL).
Check the AC output of the stator. Set your meter to read AC on the 100+ scale. Start the engine and read each pair of terminals in the same order as you did above, 1~2, 1~3, 2~3. At idele you should get 20~25 volts AC on each pair. Increase RPMS to 4000 RPM and read voltage on each pair again. Voltage @ 4000 RPM should be around 100~110 volts AC. All pairs should read equal voltages. If one pair reads much less than the others, or if all read smuch lower voltage than specified, the stator may be defective or there may be a connection problem at the stator connector where it connects to the main wiring harness. If you get questionable readings, you’ll need to retest at the stator connector located behind the side/center covers below the rider’s seat.
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