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Charging System issues- GS250t

  • Thread starter Thread starter ChicagS25o
  • Start date Start date
I found the connection where the stator meets regulator, it was at the top of the bike, the regulator wires were ruining behind another compontent. 3stator wires, 5 r/r including the ground.

In the process of checking the wires and connectors and then get to testing...
 
On my 250, I found a short in the wiring harness under the seat. The ground wire inside the wrapped harness had been pressed against a 12V source, and the insulation had failed. This had zapped both the R/R and the stator.

If/when you find the R/R and stator are toast, don't forget to look for the original cause. Because of the PO's mods, you'll have more to do, of course.

Do you have a wiring diagram? Actually the 250's wiring is quite similar to the larger bikes - close enough to find your way about.
 
i do have wiring diagrams in my manual.

i checked the wires and connections last night- they all seem to be ok. didnt get to test the components yet, letting the battery charge up and ill check the stator and r/r tonight or saturday.

i talked to another member last night, and he suggested , while im at it, to upgrade some of the connectors (just get new spade connectors)... any thoughts on that from anyone else?

didnt find anything faulty, BUT the r/r was grounded to the frame and not to the (-) battery terminal - thats something i want to reroute correct?

by grounding to the - terminal, it creates less resistance, according to the stator papers....
 
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I grabbed a Battery Tender, fully recharged the battery and started my tests.

Fortunately- very early on I found a poorly connected ground wire, I was able to re-do that properly and checked the circuits. Everything turned out ok, and the bike started on one push.

I took it out 3 different times today, for about 5 miles each ride, and it ran great. For now, no major component faults.
 
Now for the question that begs to be answered.
What is the charging system voltage, measured at the battery @? rpm's...
 
well its been a while, i was able to squeeze out a couple extra weeks of riding by just charging the battery every so often.

now that there's snow and salt out, i ran the diagnostic tests, where i stand right now, my stator is bad.

At 2500 rpm the voltage was 12.29. I went thru the other initial tests according to the stator papers, and then began section B (the actual stator tests). During all of this i replaced a few connectors.

The resistance between all of the stator legs was 0.2. This points to bad stator.

There was infinite resistance when i tested the continuity to the ground.

The last was for the AC voltage output....not all the outputs were equal to each other (one pair was lower than the other 2 pair), and was below 60v volts.

So where i stand based on the stator papers/bass cliffs pictorial is that i need to replace the stator.

Unless anyone has any opposing advice, i will be ordering one.
 
I have one on that parts bike if you need it or are you going to get a new one ?



ChicagS25o said:
well its been a while, i was able to squeeze out a couple extra weeks of riding by just charging the battery every so often.

now that there's snow and salt out, i ran the diagnostic tests, where i stand right now, my stator is bad.

At 2500 rpm the voltage was 12.29. I went thru the other initial tests according to the stator papers, and then began section B (the actual stator tests). During all of this i replaced a few connectors.

The resistance between all of the stator legs was 0.2. This points to bad stator.

There was infinite resistance when i tested the continuity to the ground.

The last was for the AC voltage output....not all the outputs were equal to each other (one pair was lower than the other 2 pair), and was below 60v volts.

So where i stand based on the stator papers/bass cliffs pictorial is that i need to replace the stator.

Unless anyone has any opposing advice, i will be ordering one.
Click to expand...
 
mriddle said:
I have one on that parts bike if you need it or are you going to get a new one ?
Click to expand...

Thanks for the offer, but i think im going to get a new one, simply because of the history the stock ones have of going bad.
 
ChicagS25o said:
no charger, but amazon is the best deal on that one, so im going to pick that up.

also had a question about an impact driver, found this one on craigslist

http://chicago.craigslist.org/nwc/tls/911492861.html

any opinions on it? should i stick with a manual one?
Click to expand...

When you get done with the stator, this is the impact driver you need. It's from sears.com, and if the link doesn't work then look up Sears item #00947641000

http://www.sears.com/shc/s/search_1...river&gobutton.x=0&gobutton.y=0&gobutton=find

When I asked for this product at a sears store hardware department, the kid said "yeah, that sound's like a good idea, but we've never sold them." Skip the kid at the store and order it on-line. You'll never regret owning one. Mine has been in my toolbox for over 30 years and gets frequent use.
 
LarryA_Texas said:
When you get done with the stator, this is the impact driver you need. It's from sears.com, and if the link doesn't work then look up Sears item #00947641000

http://www.sears.com/shc/s/search_1...river&gobutton.x=0&gobutton.y=0&gobutton=find

When I asked for this product at a sears store hardware department, the kid said "yeah, that sound's like a good idea, but we've never sold them." Skip the kid at the store and order it on-line. You'll never regret owning one. Mine has been in my toolbox for over 30 years and gets frequent use.
Click to expand...

thanks for the link. Ive bought the impact driver and im just waiting on the stator to arrive.
 
A little update:

The stator arrived last night (from RM Stator), i have it installed. In the time i was waiting for it to come i cleaned up the crankcase cover real good.

Just waiting on the crankcase gasket to come from bikebandit along with some oil filters/o-rings...unfortunately those wont be arriving til wednesday.

So in the meantime i guess its back to polishing......
 
And how did the old stator look? Cooked?

Again, have a look at the wiring harness under the seat; there were pinch points there inside the wrapped harness that triggered the R/R and stator failures I saw on my 250.
 
mf70 said:
And how did the old stator look? Cooked?

Again, have a look at the wiring harness under the seat; there were pinch points there inside the wrapped harness that triggered the R/R and stator failures I saw on my 250.
Click to expand...

The stator looked terrible, it was cooked, parts of the wiring and insulation that connected to the stator itself were literally crispy. im planning on uploading some pics very soon.

as far as the wiring harness goes- that was my intial point of investigation. everything looks ok, but i redid all of the connections with insulated blade connectors. there was nothing really wrong with the old ones, but the clear insulation was so filthy, i had to cut it open to make sure it wasnt burned.
 
Good news- the stator came a day early; i installed it and gave the bike an oil change.

It started right up and i checked the DC volts from the battery, at idle it was 14.72. I flipped on the lights and idled it and it was at 14.25. So it looks like everything is charging correctly.

Just for the sake of making sure, i ran thru a few of Basscliff's test:

1. The resistance between each stator leg was .5 ohms, they were all equal.

2. There was also no resistance with any leg when i tested the continuity to the ground.

3. Finally at 4000rpm the AC volts from each leg were all equal, at 68 AC volts.

So everything appears to be operating properly. I think i can close the books on this one unless anyone has input otherwise?
 
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Hey Mr. ChicagS25o!

Nice work! It seems you have solved your charging issues. Have you run a dedicated ground wire from the r/r to the negative terminal of the battery? Have you cleaned all of the electrical connections and grounds? These will go a long way to ensure the health of your charging system. Good going.

Thank you for your indulgence,

BassCliff
 
BassCliff said:
Have you run a dedicated ground wire from the r/r to the negative terminal of the battery? Have you cleaned all of the electrical connections and grounds?
Click to expand...

I sure did.

i cleaned up and replaced the connections with the blade connectors.

And then also, a guy i know had this pictorial gudie, said to run that ground right to the (-) terminal, so i followed his advice and did that :D
 
ChicagS25o said:
I sure did.

i cleaned up and replaced the connections with the blade connectors.

And then also, a guy i know had this pictorial gudie, said to run that ground right to the (-) terminal, so i followed his advice and did that :D
Click to expand...

OK then. I hope that guy knew what he was talking about. :D

Thanks for sharing your success story. :clap:


Thank you for your indulgence,

BassCliff
 
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