new HHB combo ignition charging system overheating stator wires..help

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Kenny Roberts

XS650 Enthusiast
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So been without my xs for a couple months due to lack of availability to me of a good used or new charging system rotor
I bought the new combo kit from Hugh's and while I'll save my review for later I'm having a serious issue with the stator wiring getting way too hot
First start up I didn't touch the wires or run it very long
Was 12.5ish volts at idle would go 14.3 upon revving it
Second time I'm running it and I get 12.6 volts regardless and barely any more on revving
I'm thinking the stator is poop .
Any help from you guys would be great as I've been down 2 months and now I'm in $500+ deep and still down wtf lol
 
It's gonna be hard for anyone to really help with how new that product is....has Hugh even posted install instructions online yet? Probably best to contact Hugh himself.
 
Don't know what's been posted .Received mine last week and have slowly been installing it after work.
Haven't contacted anyone yet either
Just looking for advice at this point as I'd really like to ride rather than look at my bike summers here
 
1st get with Hugh, next PM me and get a system I been selling for over 10 years with no problem. Gary
 
2 months loss of bike use and now $500/$600 spent as well. I suggest that its probably not a good idea to buy new unproven products. You are actually the beta tester, so you can expect to see failures.

www.customrewind.com has a long reputation for doing high quality rewinds of motorcycle rotors, such as used on our bikes. Cost is likely less than $150.
 
Kenny Roberts said:
So been without my xs for a couple months due to lack of availability to me of a good used or new charging system rotor
I bought the new combo kit from Hugh's and while I'll save my review for later I'm having a serious issue with the stator wiring getting way too hot
First start up I didn't touch the wires or run it very long
Was 12.5ish volts at idle would go 14.3 upon revving it
Second time I'm running it and I get 12.6 volts regardless and barely any more on revving
I'm thinking the stator is poop .
Any help from you guys would be great as I've been down 2 months and now I'm in $500+ deep and still down wtf lol
Click to expand...

On Hughs site, in the "Complete XS650 CDI System" product description

No 13 ; Unmatched Hugh's HandBuilt Tech Support and Install Articles, wiring diagrams, and more – coming as soon as we start shipping!

Ring Hugh.



hooser said:
1st get with Hugh, next PM me and get a system I been selling for over 10 years with no problem. Gary
Click to expand...

Good mates.

Almost like a virus
 
I agree with you on the beta testing but claims were made that the setup was tested etc
I ruined my rotor removing it so now I need a complete one to replace it
Used a crappy 2 jaw puller on it as it was shorted and I figured I was done with stock stuff....dammit lol
 
I've now done a cursory exam and the windings that were once white are now brown .
Not more than 10 minutes total time on them
No pinched wiring etc which leads me to believe poor quality or design flaw
Will try to post a pic later
 
Kenny Roberts said:
I agree with you on the beta testing but claims were made that the setup was tested etc
I ruined my rotor removing it so now I need a complete one to replace it
Used a crappy 2 jaw puller on it as it was shorted and I figured I was done with stock stuff....dammit lol
Click to expand...

Yes, I bet "claims" were made. That's called "marketing" , which means you tell the customer whatever the customer wants to hear. Marketing hyperbole is alive and well.
Anyway, you have no worries, as you bought it from the seller who always claims to fully back his customers with an amazing product warranty. You'll almost certainly get a replacement at no cost to you. Just watch out for the "bad batch" explanation that is commonly used by some sellers, to explain failures of low quality products. Your replacement might be from the same "bad batch".

If you had used the correct rotor removal tool, and had the rotor rewound, you would have a lot more money in your pocket.
 
Well in my defense and a rather weak one the kit had a removal tool in it so thought I was good.It only fits Hugh's flywheel not the OEM and by the time I was to it I figured it was no longer needed and just skipped making a proper tool .Duh I know my bad
 
Ill check those solder joints better when the bikes 3 year old owner as and my pit crew partner arrives later
I pushed it in the corner and grabbed my other bike for a much needed ride :)
 
The powerdynamo system rotor puller works on both, go figure. Must be a well designed system.
 
Retired, I don't know you very well just you post. So I am wondering what you have in Dollars for your ignition, say you had to replace stator, rotor, pamco stuff, regulator, rectifiers and coils please let us know.
I can do it for $550.00 or less with a reliable system, that in case you are on the road and leave you lights on or the battery takes a shit you can still get home. Is that worth anything to you, have you ever had problems with the pamco stuff as many others have? Thanks Gary
 
Lets not turn this into another shit fight about stock vs PMA. It's been done to death.
Both have pros and cons. Sometimes people buy a bike with a totally stuffed or missing charging system, missing ignition parts etc, in which case a PMA or this new kit of Hugh's might be a good option. Im sure there are probably thousands of PMA kits out there that have been problem free, but also maybe there have been some quality control issues over the last year.

Lets just help the OP work out what's happened, and if need be get another replacement. To me, this sounds like a connection in the stator winding has been badly soldered and failed.
 
Having been through this PMA thing during the last month or so, I have to say Hugh is a great guy who stands behind his units. I mean when your name is on the line and you are trying to earn a living catering to the likes of us bike nuts...come on, let's be fair and supportive of those who work to support us. If you want total reliability, get a 2016 BMW or whatever you can afford. In the meantime, know that we are riding a delicate finite system which breathes and burns and needs to generate its own electricity and there is no one way to do it. And isn't it fun to try to figure it all out?
Peace All!
 
How does the HHB stator connect to the stock wiring? Are the connections solid? Does the bike side plug have corrosion. That magnet spinning in the stator is going to induce current. It has to go someplace and it's going to be shed as heat. An overheated stator tells me the connections to it are faulty. Likely, nothing is wrong with the HHB stuff. Find the faulty connections. Better, get some good contact cleaning solvent and clean all the connectors on the bike. Get the kill switch, too!
 
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