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Message started by Lucky on 09/18/17 at 11:48:33

Title: Replacing Stator Question?
Post by Lucky on 09/18/17 at 11:48:33

I'm new here, and apologize for not doing an intro.... but I'm trying to get my g/f's 2000 Savage going.

Do you have to remove the Pulley and belt like Clymer says, to replace the stator, or will the side cover come off the engine with the pulley still in place?

Thanks, and any tips or tricks to changing the stator would be appreciated as well.

Title: Re: Replacing Stator Question?
Post by Dave on 09/18/17 at 11:50:41

I recently put in a lighter flywheel that Armen machined, and I didn't take off the pulley or belt when I removed the side cover......however the wires do go behind the pulley as they exit the case - it might be easier with the pulley removed.

Title: Re: Replacing Stator Question?
Post by Lucky on 09/18/17 at 11:57:18

Thanks dave

Title: Re: Replacing Stator Question?
Post by Lucky on 09/18/17 at 15:16:56

Update, didn't need to take anything extra off! GREAT SUCCESS! Clymer sometimes makes things much harder than they need to be....

Title: Re: Replacing Stator Question?
Post by Lucky on 09/24/17 at 10:45:36

Ok, new question.

New battery
New Stator
New Voltage Regulator/rectifier

Still will not put out more that 13V at any rpm, struggles to get to 13V actually. Put old regulator back on, same result!

What else am I missing? Please help, I'm getting super frustrated, I've never had this much trouble on any other bike!

Title: Re: Replacing Stator Question?
Post by Ruttly on 09/24/17 at 12:45:38

Try a different meter and double check connections,battery & grounds & at starter relay/selenoid

Title: Re: Replacing Stator Question?
Post by Gary_in_NJ on 09/24/17 at 13:07:25

It could be a bad ignition switch. I've seen this problem before and was surprised when I found out it was the switch.

Title: Re: Replacing Stator Question?
Post by eau de sauvage on 09/24/17 at 23:11:31

2229232D662A24292623480 wrote:

Still will not put out more that 13V at any rpm, struggles to get to 13V actually. Put old regulator back on, same result!

I had a similar issue recently on GS500, there were two problems, 1 was my cheapo multimeter, it was not reliable. Bought a Fluke 101 (the cheapest available for 50 bucks) which already improved my ability to confidently diagnose stator problems.

2nd problem that was causing the issues was simply the connector plugs. They were in good condition with no corrosion, nevertheless disconnecting and spraying with contact cleaner fixed everything, including the main problem of reaching 14V at 2500rpm then gradually dropping to 13V as i reached 5,000 rpm.

Title: Re: Replacing Stator Question?
Post by batman on 09/25/17 at 12:10:40

It may be that your testing wrong ! You should be unplugging the three wire connector (yellow wires) going from the alternator to the voltage regulator and testing for AC volts-3 tests between each of two of the wires,@ 5,000 rpm ,you should be reading 100 volts AC. When you test for DC volts across the battery ,the reading you get depends on many factors, rpm, battery charge, how long you run the bike, if you remembered to turn on the high beam ,and how long you took to start the motor. Finding the DC voltage dropping across the battery as you test at higher rpms may just be the regulator doing it's job.13 volts may seem low ,but it's still higher than a new fully charged battery will read at rest(usually 12.2-12.4)

Title: Re: Replacing Stator Question?
Post by eau de sauvage on 09/25/17 at 20:10:10

Here's some great resources that I used...

http://bbburma.net/Documents/JohnBates_ChargingCircuitTests3.pdf
http://www.electrosport.com/media/pdf/fault-finding-diagram.pdf
http://www.electrosport.com/technical-resources/library/diagnosis/pdf/diode-testing-guide.pdf

@Batman, I don't think 13 is enough.

Title: Re: Replacing Stator Question?
Post by batman on 09/26/17 at 11:51:34

Anything over battery voltage(12.3) is enough to charge the battery. Why not do a test ?let the bike sit overnight ,check the battery voltage before starting,take it for a ride 50-100 miles,park it over night and test voltage again ,if it's the same your golden.If not I'll concede you have a problem.

Title: Re: Replacing Stator Question?
Post by justin_o_guy2 on 09/26/17 at 12:07:15

IOW, if the battery tests good and it keeps a charge being ridden regularly, is there a problem?
What problem are you solving and what troubleshooting steps led you to it?

Title: Re: Replacing Stator Question?
Post by eau de sauvage on 09/26/17 at 23:38:47

@Batman, if you have a new battery fully charged and healthy reading say 12.7 with the static charge drained, then turn on the electrics the voltage will drop .5V maybe .6 which needs to be taken into account.

A better test of the battery is to see how low the voltage goes when it cranks over.

@JoG, I can say from recent experience on my GS that it's had a crappy wet battery in it probably for 5 years and would turn over instantly and all that even after a few low levels. However I checked it a couple of months ago and to my horror all cells were uncovered a fair way, however I resurrected it to see what would happen and it came back as good as new...

It was always 12.6 after the static charge had drained and had enough cranking voltage to turn over instantly. So I just ignored it. Never hesitated to start, then two weeks later we went on a long ride, pulled over a couple of times to get petrol no problem, then later we turn down an interesting looking side rd. Stop for lunch, go to start the bike and it is completely dead, not a flicker of life, I was convinced it must be a fuse or electrical, until I saw the tiniest glimmer of an oil light.

Fortunately the local Suzuki store was only 20mins ride away and it was a public holiday the day before, so it was all good. But there's a warning of how an apparently good battery can be inches away from death. Had we been out the day before, then I would have been up shite creek, sans paddle as they say.

Title: Re: Replacing Stator Question?
Post by batman on 09/27/17 at 13:04:41

EDS,I thought we were talking about the charging system not batteries, but while we're on the subject .Why do you think the water level in your battery was so low? could it be that your voltage regulator/rectifier is on it's way out,over charging your battery and "boiling " the water out ? 12.7 volts sounds awfully high to me, 12.3 being the norm.I'd have it tested.

Title: Re: Replacing Stator Question?
Post by verslagen1 on 09/27/17 at 14:00:55

2526332A2629737F470 wrote:

the voltage regulator/rectifier does not sense battery charge and reduce the voltage when the battery is full. Any long ride is going to overcharge the battery.

Title: Re: Replacing Stator Question?
Post by Lucky on 09/28/17 at 10:39:39

All I know is on all 4 of my bikes, they all charge when running and testing at the battery, over 14 volts.

12.3 is not the normal for a battery sitting, should be closer to 12.7-12.8. in my experience.

I took it for a ride yesterday just about 10 miles, didn't have time nor desire to ride it 50-100 miles, too small of a bike for me. let it sit over night, going to see what voltage is today.

also, just a side note, I don't know why a bike this simple has all the safety switch bull nuts on it, they've made the electrical system about 1000 times more difficult than it needs to be.

Thanks for the replies

Title: Re: Replacing Stator Question?
Post by Lucky on 09/28/17 at 10:43:33

2526332A2629737F470 wrote:

12.7 is not high... and 12.3 is NOT the norm. 12.3V is actually about 60% charged, 40% discharged. (see 2nd hyperlink below)

https://www.batterystuff.com/kb/frequently-asked-questions/powersports-batteries-faq/12-volt-battery-reading-13-volts.html

see this one after number 6, gives a good chart of what voltage should be.

https://www.batterystuff.com/kb/articles/battery-articles/battery-basics.html