How to fix common regulator/Stator failures

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

  1. mello dude

    mello dude Member

    Country:
    United States
    Joined:
    Jan 3, 2006
    Messages:
    3,888
    Likes Received:
    246
    Trophy Points:
    93
    Location:
    Southwest Ohio
    Map
    Chances are the connector is burnt up, and thats not helping. You do need to do a stator test to find out if its ok, although for some reason, the '06s and '07s had a high stator fall out. - The full test is in order. 11.88 on a new battery is trouble.
     
  2. RRloves2RRIDE

    RRloves2RRIDE New Member

    Country:
    United States
    Joined:
    Jul 21, 2018
    Messages:
    35
    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.
     
  3. skimad4x4

    skimad4x4 "Official" VFRWorld Greeter

    Country:
    France
    Joined:
    Jul 5, 2009
    Messages:
    2,098
    Likes Received:
    292
    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.
  4. raYzerman

    raYzerman Insider

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    889
    Likes Received:
    299
    Trophy Points:
    93
    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.
  5. squirrelman

    squirrelman Member

    Country:
    United States
    Joined:
    Jul 27, 2006
    Messages:
    8,962
    Likes Received:
    451
    Trophy Points:
    98
    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.
  6. RRloves2RRIDE

    RRloves2RRIDE New Member

    Country:
    United States
    Joined:
    Jul 21, 2018
    Messages:
    35
    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
  7. 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??
     
  8. raYzerman

    raYzerman Insider

    Country:
    Canada
    Joined:
    Dec 3, 2019
    Messages:
    889
    Likes Received:
    299
    Trophy Points:
    93
    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.
     
  9. 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
     
  10. rhoderage

    rhoderage New Member

    Country:
    Canada
    Joined:
    Aug 13, 2014
    Messages:
    138
    Likes Received:
    24
    Trophy Points:
    18
    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...
     
  11. 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
     
  12. OOTV

    OOTV Member

    Joined:
    Aug 20, 2011
    Messages:
    6,460
    Likes Received:
    941
    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.
  13. Simon Edwards

    Simon Edwards New Member

    Country:
    United Kingdom
    Joined:
    Mar 16, 2021
    Messages:
    34
    Likes Received:
    10
    Trophy Points:
    8
    Location:
    Berkshire
    Map
    Does anyone have any UK recomendations for sourcing a good Mosfet R/R for a Gen4?
     
Related Topics

Share This Page