How to fix common regulator/Stator failures

Discussion in '5th Generation 1998-2001' started by Rubo, Jul 7, 2012.

  1. RRloves2RRIDE

    RRloves2RRIDE New Member

    Country:
    United States
    Joined:
    Jul 21, 2018
    Messages:
    36
    Likes Received:
    4
    Trophy Points:
    38
    Location:
    California
    Thank you. After a cleanup of the connection, 3 yellow wires were consistently in 0.5 ohm resistance. Checking ground tomorrow. May order parts tomorrow anyway.
     
  2. skimad4x4

    skimad4x4 "Official" VFRWorld Greeter

    Country:
    France
    Joined:
    Jul 5, 2009
    Messages:
    2,269
    Likes Received:
    369
    Trophy Points:
    113
    Location:
    French Alps & London
    Map
    If the connector is a pain - rather than testing the stator I would simply unbolt (carefully) the stator cover and have a look inside - it will only take a few minutes.

    If it looks Ok then reinstate the cover if necessary replace the gasket. If you are greeted by the smell of burnt or fried electrical windings you need a new stator anyway which will come with a new connector. However if the stator connector is melted I would eliminate it entirely and simply solder and heat shrink that connection. Don't get stressed over which of the three yellow wires goes where on the RR - they are all the same. But before permanent soldering the connections, do temporary connections with insulation tape to test the RR is working. If your RR tests OK you are lucky - if not get a better Shindengen one from Roadstercycle.com


    SkiMad
     
    RRloves2RRIDE likes this.
  3. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    Just my opinion, but replacing the stock R/R with a mofset will take the heat off a stator... stator if testing OK and no coils "black" should be OK... natural to heat up in certain areas because they are cooled by oil splash not always uniform, e.g., CBF1000 has a poorer oil cooling than most. Smaller stator capacities and they tend to work harder to keep up to charging needs/loads if you have a lot of accessories, i.e., not a lot of reserve power, uses more battery reserve, which in turn needs more recharging as you ride.
     
    RRloves2RRIDE likes this.
  4. squirrelman

    squirrelman Member

    Country:
    United States
    Joined:
    Jul 27, 2006
    Messages:
    9,839
    Likes Received:
    743
    Trophy Points:
    128
    Location:
    Buffalo, NY
    Map
    RED PLUG

    just repeating for anyone who missed earlier:

    the red plug on top of starter relay needs inspection for melting and burning as any added resistance there lowers charging voltage and 's a common problem.

    Picture1-12-2020 036.jpg

    Picture1-12-2020 144.jpg
     
    Last edited: Jul 7, 2020
    RRloves2RRIDE likes this.
  5. RRloves2RRIDE

    RRloves2RRIDE New Member

    Country:
    United States
    Joined:
    Jul 21, 2018
    Messages:
    36
    Likes Received:
    4
    Trophy Points:
    38
    Location:
    California
    And the bent wires don't help. My 30A fuse housing was burned but fuse did not blow. Not quite melted, but I thought burned would have met threshold to blow it. I replaced fuse holder and wiring. Now I have starter power and am charging fine with rewound stator fr Custom Rewind and SH847. Instructions with the SH847 really could be a little better. If you have a 6th gen, DO NOT buy the adapter plate that is an extra charge. It does not fit 6th gen. Got another plate - thanks Mello Dude. Will install this weekend. Been a steep learning curve in this project and am sure I could have done better if I did not have to work so much during COVID. My garage hours were 7 - midnight.
     
    Last edited: Aug 29, 2020
  6. NorthernFirepower

    NorthernFirepower New Member

    Country:
    United States
    Joined:
    Feb 16, 2011
    Messages:
    11
    Likes Received:
    0
    Trophy Points:
    1
    Location:
    Central WI
    Map
    Hello all, did a ElectoSport Stator and R/R replacement a few years back and when cleaning my chain I noticed a harness zip tie broken and hanging...upon inspection it was clear that it was melted prior to breaking. *sigh*

    After very short digging, it was clear that the Stator to R/R connection was toasted along with 1" of wire insulation going both ways. After testing out the R/R and Stator, I've decided to solder the wiring in place of any connectors.

    When cutting and stripping the stator wiring, it was very obvious that it was coated in 10w-40 engine oil! Anyone else experience this? Wondering if the wicking oil is causing the connections to actually burn up with the high heat it produces? More importantly, worried that my new soldered connections will burn up in time due to heat + oil??
     
  7. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    It may have been dielectric grease from a previous treatment of the connectors, or it could be a little seepage from valve cover half-moons, or even travelling along from the stator grommet to the engine cover? All you can do is look..... you can clean it off and spray on some aerosol foot powder and the source most likely will be revealed.
     
  8. NorthernFirepower

    NorthernFirepower New Member

    Country:
    United States
    Joined:
    Feb 16, 2011
    Messages:
    11
    Likes Received:
    0
    Trophy Points:
    1
    Location:
    Central WI
    Map
    Definitely engine oil, I'm pretty confident that it's wicking from oil on the stator itself. Reading from the Aprilia forum, they have similar issues and solve it by ensuring the wiring coming out of the stator is as vertical as possible. I'll look at it tonight and see if I can do similar, plan to also run the bike and test the wire temp along the wring compared to the new soldered joint. Time will
     
  9. rhoderage

    rhoderage New Member

    Country:
    Canada
    Joined:
    Aug 13, 2014
    Messages:
    148
    Likes Received:
    31
    Trophy Points:
    28
    Location:
    Nova Scotia
    Map
    If oil is coming out of the stator, is the black rubber seal piece that the wiring enters/exits the stator from installed properly in its groove/channel? It shouldn't let any oil out...
     
  10. Jeffvfr800

    Jeffvfr800 New Member

    Country:
    United States
    Joined:
    Feb 10, 2021
    Messages:
    1
    Likes Received:
    0
    Trophy Points:
    1
    800FithGenSatorConnector.jpg I cannot understand how to open this connector. It is from the stator on a VFR800 Fith generation. I see what appears to be a lined button as shown in the photo. Please tell me what I need to do to open this connector. Best Regards, Jeff
     
  11. OOTV

    OOTV Insider

    Joined:
    Aug 20, 2011
    Messages:
    6,479
    Likes Received:
    949
    Trophy Points:
    143
    Location:
    Anaheim, Ca.
    Jeff,

    You should be able to press that little tab you see there and pull the connectors apart. Sometimes these can be stubborn or "melted" together if they got really hot. That's essentially it.
     
    skimad4x4 and mello dude like this.
  12. Simon Edwards

    Simon Edwards New Member

    Country:
    United Kingdom
    Joined:
    Mar 16, 2021
    Messages:
    51
    Likes Received:
    18
    Trophy Points:
    8
    Location:
    Berkshire
    Map
    Does anyone have any UK recomendations for sourcing a good Mosfet R/R for a Gen4?
     
  13. Scubalong

    Scubalong Official Greeter?

    Country:
    United States
    Joined:
    Mar 11, 2008
    Messages:
    9,239
    Likes Received:
    25
    Trophy Points:
    93
    Location:
    O.C Suck
    @Melo dude
    Thanks for updating the thread. I am looking to send my stator to Gary and was wondering if he is still up and found your note above.
    I will give him a call. Cheers brother...:drink1:
     
    mello dude likes this.
  14. vfrgiving

    vfrgiving New Member

    Joined:
    Apr 2, 2021
    Messages:
    210
    Likes Received:
    88
    Trophy Points:
    28
    I'm sorry to quote a years old post, but I had an old battery die over the weekend and replaced it. I did the standard checks on the charging system and came to read this thread. I found something in the 5th generation service manuals that caught my eye in the process of doing the tests, and then saw this post.

    In the older version of the 5th generation service manual, like the digital one that is available here that has an issue date of 1998, go to section 16. In the specifications table they have a table for Regulated Charging voltage at 14 - 14.8V @ 5000rpm.

    Then in the trouble shooting steps section Honda gives a Standard of 14 - 14.8V @ 5000 RPM.

    I have a more recent physical copy of the service manual that covers through the 2001. Honda made a major revision to section 16. The specification table no longer lists a regulated voltage charging range. This column is gone completely. The standard has also changed for troubleshooting. That is now: measured battery voltage < measured charging voltage < 15.5V @ 5000rpm.

    Cycleman1's point that different regulators can be set differently is the reason Honda made this major edit I think.
     
  15. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    The latest mofsets should restrict charging voltage to 14.5 max. 15.5V will start frying things..... most I see on my various bikes is 14.2-ish.
     
  16. vfrgiving

    vfrgiving New Member

    Joined:
    Apr 2, 2021
    Messages:
    210
    Likes Received:
    88
    Trophy Points:
    28
    If I had a regulator start approaching 15V I'd probably pull it. I just thought it was interesting for Honda to drop the specification in the updated service manual. They're stating in the revised standard that resting battery voltage (specified at 13 - 13.2) < charging voltage (anything above 13.2) < 15.5V at 5,000 rpms is considered fine.
     
  17. RC36VFR

    RC36VFR New Member

    Country:
    United States
    Joined:
    Nov 12, 2019
    Messages:
    2
    Likes Received:
    0
    Trophy Points:
    1
    Hey VFRmeisters,
    Has anyone mounted an SH847 on a Gen4? I like the cool operation thing, but
    the existing plate is a bit narrow AND short, not sure the connectors/cables will fit.
    Reccomendations? Advice?
    Thanks all,
    Scotty
     

    Attached Files:

  18. raYzerman

    raYzerman Member

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    1,228
    Likes Received:
    450
    Trophy Points:
    113
    Location:
    Millgrove, ON
    Map
    If you want a series r/r, try one from a Versys 1000 (2015-up) it's a SH866 in a smaller format (same size as a FH020).
     
  19. RC36VFR

    RC36VFR New Member

    Country:
    United States
    Joined:
    Nov 12, 2019
    Messages:
    2
    Likes Received:
    0
    Trophy Points:
    1
    Thanks Rayzer, could not find the smaller `866, so I ended up getting the FH020 from Jack at RoadsterCycle.
    Got the R/R and cables installed quick. Easier than peasy.
    Just need to add a PEM nut to the mounting plate to make it pretty.
    Back on the road WOOT
     
Related Topics

Share This Page