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brand new stator failed, how could this happen?

  • Thread starter Thread starter radbrad
  • Start date Start date
barsnake said:
You guys are tough! I made my own analysis of what was happening to my 78 GS1000 and used parts that were available. It's been 10 years without any problems. I don't argue with success. I didn't say it was the best solution; it's just another approach that didn't cost a fortune. To answer your question...my shopping cart has a generator to power my soldering iron.
Click to expand...

I'm not questioning what you did so much as your analysis. For some reason given the already constrained performance of the GS charging system, the way you use your GS has proven that this solution works for you. You are probably one of the few and perhaps only people that have "fixed" your charging system this way. Thats great. :-k

However when you offer up this solution to somebody else, you have to understand that you have opened your "solution": up to public scrutiny. As best your solution is mis guided and based on incorrect analysis of cause and effect. It has not bit you yet but that is hardly a proof of principle that would stand up to the slightest scrutiny.

You can take what I posted and put it to good use or you can continue on in blissful xxxorance. It is up to you. :-#

Pos
 
Glad you've got the pimped out shopping cart. :D Heck, you're probably the only hobo in town with an extra refrigerator box for your bike.

As you noted, you can't argue with your success. However, as others have noted, the resistor solution would be a very poor solution for most people, and that's sort of the real issue behind my "hobotech" remarks.

It would be a very bad idea to simply slap in a scavenged resistor or two without bothering to clean all the connections, test your stator and rectifier, and achieve some understanding of the systems involved.
 
update - fixed charging system, broke something else

update - fixed charging system, broke something else

OK, thanks to everybody's help, and BassCliff's web site, I was able to successfully replace my stator and RR on the 82 GS 650G. I cleaned all the bike's electrical connections, ran the RR ground to the battery, and bypassed the circuit to the headlight that is unnecessary in bikes that have no headlight switch, as suggested on BassCliff's directions on his website. It charges beautifully now, at the voltage said to be normal according to the stator papers.

Embarrassingly, I think it was my fault the new charging system I had put in last year burned out. I had cleaned many of the electrical connections then, and the one where the RR hooks into the stator was a 4 prong clip type connections, which I cleaned the female end of by sticking in a file that was too big for the spade size holes. I think I damaged the connection while doing that, one of those connections looked burned out, it probably wasn't fitting properly.

Though I was really happy to see my charging system working great after installing the parts myself this time, I noticed a little oil leaking out of the bottom of my left crankcase cover.. When I checked the bolts of the cover, I discovered that I could turn them all a bit tighter. This was surprising because I had already tightened them well, I THOUGHT, and put locktight blue on all of them (one day earlier). So I went around tightening all the bolts a little more when, to my horror, I broke a bolt, the one right on the bottom of the crankcase cover where the oil was leaking.

I was hoping maybe it was tight enough not to leak oil, but when I started her back up, some oil started to well up there and leak. I should mention that I did of course use a new gasket when putting back on the crankcase cover in the first place and it isn't sticking out anywhere or anything - I think it is in place properly.

I don't know what to do now, I think I have to take it into the shop to get the bolt removed from the engine... My plan now is to order a new set of left crankcase cover bolts, have the shop drill out the bolt and put it back on correctly - unless anyone has any other suggestions how I might do this myself. I don't have many tools and this is my first experience doing mechanical work on my bike.

Another mistake I made was that I took the bolts out of that left crankcase cover without realizing that they were different sizes, even though BassCliff's directions clearly say that some are longer and you have to remember where they go. I found that all the bolts are the same except for two - one is a little longer than the rest and the other is a bit longer than that. I played around with them and thought I was able to figure out where the longer and longest bolts go by trial and error, but it is possible I screwed that up. If anyone has a schematic showing where these bolts go, I could use one. Hopefully, IF I could order new bolts from Suzuki, they will show me where the 2 odd bolts go.

Also, is locktight blue the correct locktight to use for this job? It is the next to strongest locktight, so that's what I took as "medium", which is what was suggested.

That all for my newbie bike mechanic learning experience reflection for today, your thoughts are welcome.

- Brad
 
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