leighd42
XS650 Enthusiast
This problem is really boggling me. I installed a HHB PMA kit in the spring and the install was dead easy as per Huge's excellent instructions. I went on a 100Km ride and when I got to my destination my battery was dead. Managed to get a charge on the battery and made it back home before she died again. I started checking the charging system and noticed that the resistance between one of the phases on the stator was infinite resistance so I pulled the rotor and stator off to have a look. One of the wires one the stator had completely come off the stator and had melted and shorted to ground causing the stator to burn up pretty bad. I was desperate to take the bike out that weekend and Hugh was on a ride that week so it was up to me to come up with a solution myself. I cleaned up the stator and re-wired it making sure this time to insulate everything properly and re-solder new wires to the phases and even put new connector's on at the Reg/Rect connection as well. All summer the bike has been running tip top, carbs tuned, plugs the perfect colour battery charging......until the other day. Jumped on the bike and the same trouble again....Pulled the stator off and this time the stator wires at the phases actually got so hot the fused together and melted the solder enough to drip onto my flywheel. So once again I have re-wired it this time I crimped ( 14Ga FT4 - fire rated wire ) to each phase and new connectors again at the Reg/Rect connection and I'm back in business again. Does anyone know what could be causing the Stator/Rotor area to be getting so hot? I would like to get a new stator but I am afraid it will burn up too unless I resolve the root problem. There are no shorts, all grounds are perfect, and I'm reading 0.7 ohms between each phase which should be spec. Any ideas would be a great help....