JNaw
XS650 Enthusiast
Hey all, hope y'all have gotten out with the nicer weather coming through in Canada here.
Anyhow, took the bike out yesterday for the first ride of the season, and now my rotor self destructed (again).
Originally it died last year, and brought it to a rotor/motor rewind shop (seems to deal with mostly vacuum cleaners but does it all). $300 later and rotor was back in action.
Put about 500km on it and then parked it for the winter.
Battery was weak trying to start it (my dumbass forgot to plug it in at my storage place over the winter) but a quick jump start and she was running great. THEN BAM, 50km later the headlight stops working (been here before)
So immediately today, rip the brushes out. Sure enough, there's a melted copper wire strand sitting there and no continuity across the rotors again. (EDIT: second look seems to be a different gauge of wire, as well as a piece of white insulation about the same length sitting in the same area, wires going to brushes are fine, so not sure where this came from just yet...)
Battery is at 11.44v (after riding with a dead alternator for atleast an hour most likely)
What's going on? When I originally got it fixed, she was charging around 13-14v.
Could the battery be bad? (Can't see that as it holds a charge just fine..) Did the rewind shop use the wrong insulation rating for the windings?
I'm at a loss here..last I checked, voltage regulator was operating fine, and stator was producing correct AC voltage on all phases. Any input would be great. Thanks.
Edit 2: A PMA kit is 285usd from Mike's XS, considering a rewind will cost about as much, may just upgrade the whole system and be done with it.
Photo attached of the carnage
Anyhow, took the bike out yesterday for the first ride of the season, and now my rotor self destructed (again).
Originally it died last year, and brought it to a rotor/motor rewind shop (seems to deal with mostly vacuum cleaners but does it all). $300 later and rotor was back in action.
Put about 500km on it and then parked it for the winter.
Battery was weak trying to start it (my dumbass forgot to plug it in at my storage place over the winter) but a quick jump start and she was running great. THEN BAM, 50km later the headlight stops working (been here before)
So immediately today, rip the brushes out. Sure enough, there's a melted copper wire strand sitting there and no continuity across the rotors again. (EDIT: second look seems to be a different gauge of wire, as well as a piece of white insulation about the same length sitting in the same area, wires going to brushes are fine, so not sure where this came from just yet...)
Battery is at 11.44v (after riding with a dead alternator for atleast an hour most likely)
What's going on? When I originally got it fixed, she was charging around 13-14v.
Could the battery be bad? (Can't see that as it holds a charge just fine..) Did the rewind shop use the wrong insulation rating for the windings?
I'm at a loss here..last I checked, voltage regulator was operating fine, and stator was producing correct AC voltage on all phases. Any input would be great. Thanks.
Edit 2: A PMA kit is 285usd from Mike's XS, considering a rewind will cost about as much, may just upgrade the whole system and be done with it.
Photo attached of the carnage
Attachments
Last edited: