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Please confirm I need a new R/R and stator.

posplayr said:
i just saw this picture; my conclusion is that these bullet connectors are cheap auto move grade with crappy cimpers. If you are going to rely on a crimp it better be good meaning quality grip properly fitted to the wire size snd well crimped. If the PO had installed a series r/r he might have gotten away with it but not a shunt r/r
Click to expand...

The low output stator had a perfect oem pigtail with grommet. I removed the yellow tails in the pic and soldered the good pigtail to the windings which I'm hoping will be ok under load. As said it is giving 80V ac between all phases at 5000 with nothing to ground and 1.1 Ohm between phases and infinity to ground with admittedly, low stress meter injecting a few Volts. Should have the 775 soon and have time to get wire from the local shop and rewind the low output stator as a spare.
On the subject of resistance measurement, I am getting slightly different readings at different times. Maybe 0.8 and then 1.1. They are always the same number. The battery is in the meter a long time :)
 
This stator I thought was a good one. Only puts out 55V at 5000, zero to ground and phase resistances all equal, infinite to ground. No identifier except 1K on the reverse. Looks to be a bit light in the wire size or number of turns ? The tail for the wye is stuck between two poles at eleven o'clock.

 
Brendan W said:
This stator I thought was a good one. Only puts out 55V at 5000, zero to ground and phase resistances all equal, infinite to ground. No identifier except 1K on the reverse. Looks to be a bit light in the wire size or number of turns ? The tail for the wye is stuck between two poles at eleven o'clock.

Click to expand...

Recall (as has been discussed here) that the maximum output current and therefore power of the stator is limited by the magnetic strength of the rotor. So even though the open loop volts/RPM is low (55V/80V=69%) , it just means that you will achieve the magnetic limit at a higher RPM.

Based on some curves, I produced a while back. Max flux (related to current) saturation of a typical rotor occurs at about 3500 RPM so expect that number to go up to 5070 RPM. It will still charge, but at lower RPM you will be proportionally lower on the available power and probably always discharging at idle (for std loads). With LED directional and headlamp it would probably be fine. You probably need about 15VAC to just start exceeding battery voltage (about 1400 RPM) so you will need a high idle to avoid discharging.

Bottom line is that winding only affect low RPM charging performance; In the 3.5-5K RPM region it is constrained by the rotor.
 
Thanks Jim. I appreciate your input. Steep curve here. For better or worse I have gone back to the other stator. With this one I knew it wasn't charging as well and I'm on filaments throughout. Waiting for gaskets and stem seals and the 775 so I can button this thing back up. A week is a long time with no ride although I have been borrowing my son's Z400B :) Everyone should have a light twin in the stable.
 
Brendan W said:
Thanks Jim. I appreciate your input. Steep curve here. For better or worse I have gone back to the other stator. With this one I knew it wasn't charging as well and I'm on filaments throughout. Waiting for gaskets and stem seals and the 775 so I can button this thing back up. A week is a long time with no ride although I have been borrowing my son's Z400B :) Everyone should have a light twin in the stable.
Click to expand...

Sorry to go into that , I would put in the correct stator as well.
 
Just an update on this saga.
The original stator is back on the bike with a good used pigtail with proper grommet soldered to the windings. The original r/r was not charging sufficiently ( ~13.2 V ) after the stator lead meltdown although it had been rock steady at 14.4 V for the last two years after the connections were cleaned up and a spg organised. I tried the original r/r with two stators. Both had even phase resistances and even no load interphase outputs, one at 56V the other at 80 V , and nothing to ground for either. Both had the same 13.2 V output with the old r/r.
With the 775 on I have 14.2 volts at 5000rpm with a fully charged battery installed.
I'm guessing that the stator lead meltdown may have damaged the r/r and somehow left the stator unharmed? Sorry for rambling on. Trying to think on paper.
 
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