Stator and wiring burn out ? - GS 550et 1980

[ukjules]

New stator arrived:

New stator arrived: Rain stops play today putting it on. (Reduced to doing it outdoors)

Bench test : Touching MM contacts together = 0.5/6 ohms
Test 1: MM set at 200ohms
Stator wires A-B, A-C, B-C
All 1.2ohms meaning 0.6ohms

Test 2: to earth MM set at 200ohms
Stator wire A,B,C
All show as 1.

So bench test all good on this brand new stator.
We all agreed bench test is good ? I'll assume yes.

Now have to test on bike :
Test 3:
- the usual charge test increasing revs and subsequent voltage increase to about 14v.
And which I'll do first ....
Test 4:
- the AC volt tests between A-B, A-C, B-C at 4-5k revs hoping for all to show > 50/60v.

Remember the last 'new' stator I tried it was 0.5v on this test clearly a fail even though that one passed bench tests. (I am still suspicious of my reading of 0.5 AC Volts but that is what it said)

Status -
New stator (original was well black after my incorrect wiring ) 2nd one I am sure was faulty.
New regulator (original charged over 16v+ after my incorrect wiring during quick retest of reg to pos terminal and not earth) so clearly was effected.
Fuses ok and we're never blown
Good battery

(Unable to do wiring checking as don't have a clue how to do it but am.willung to try .....- but this only necessary if the above all pass and still fails to charge bike at increased revs)
I hope to god that it works .....

Will do work this eve after 7pm or Def tomorrow. Will update. Hold your breath !!

Update - stator on - more rain but may finish this eve ...... Worried about using old gasket but using the fantastic threebond sealer as well so should be ok .

 

[ukjules]

Results :

All put back together with new known to work reg , battery and new stator that bench tests ok. All fuses ok before and after test. Stator same type from m&g - UK company as last one that gave same result.

- it still will not charge ! Zero change on battery as revs increases and AC Volts 0.2 on 200 setting on all three wire options off stator.

Can anyone tell me how to find this fault ?
Iv changed everything ?
I simply don't believe 2 new statora are wrong although it does not charge ?

Where on earth can the problem be now ? The bike is fine bar it will not charge !
Or do I go with the check and say this stator too is faulty ?

 

[pdqford]

Wow! And weird!
All I can suggest is doing some double checking.

Good numbers when you checked resistance between the three stator wires and the three wires to ground,
Check to see if you get all the same resistance readings with the stator installed.
(Hopefully the wires didn't get damaged in the install process.)

If you don't detect any DC voltage at the battery,
check the voltage at the positive wire coming out of the R/R.

Check to see that your rotor still has the magnets in place.

I'm waiting for someone to come along that has some better suggestion.

 

[ukjules]

Way forward:
(If you don't detect any DC voltage at the battery,
check the voltage at the positive wire coming out of the R/R.​) - I have nit tested this before.
I like this test and will do It tomorrow but I don't detect any DC voltage increase at the battery terminals to be specific

Yes same resistance when installed

- so I check on mm, neg on mm to neg on battery and pos on mm to the POS wire on regulator which goes to the loom. And that should show I assume an increase if I do It running ?

As for other tests I have done them as it is installed and running !!!

Results am tomorrow

 

[pdqford]

One other test I didn't see among your tests:

Like when you did the AC voltage check at 5000 rpm between A/B, B/C, and A/C (what numbers did you get?)
also need to do AC voltage check at 5000 rpm between A to ground, B to ground, and C to ground,
looking for very low AC voltage numbers.

 

[ukjules]

Test you ask for is done in analysis !!!!! Test 4
Fail ! 0.2v when I wanted 50-60v on all options

Not done this one:
also need to do AC voltage check at 5000 rpm between A to ground, B to ground, and C to ground,
looking for very low AC voltage numbers.​

 

[ukjules]

Ok testing.

- battery connected , ignition off - I get 12.6 v at loom lead to regulator. So power getting to Reg.
I think this is one of the tests you meant .

You did ask for .....
(If you don't detect any DC voltage at the battery,
check the voltage at the positive wire coming out of the R/R.​)​
Which doesn't make any sense. I get power going to the regulator yes 12.6v disconnected .
And
OF course I get voltage at the battery -12.6,v

I am now getting confused. I simply don't understand what I am meant to be seeing . Does volts come out of reg obviously too ? How am I getting volts to it at same.time ,?

I'll do other running test now

 

[ukjules]

Test - 4-5k revs . Mm on neg and each stator wire disconected from reg. Each show 0 acv

 

[ukjules]

I think I and we have reached the end . I cannot understand why this is.not charging unless I am putting on wires in wrong place from reg / stator.
3 yellow to yellow on reg
Power on reg to loom where I have even marked as such last 10 years.
Neg black lead from reg the neg on battery.

If anyone has an idea please inform.
I have done every test. Had 2 new regs and stators. Battery is fine. Fuses fine (only 4in side panel). Used both regs that work fine on another bike. Battery works on other bike.

Iv never ever been defeated by a bike and dragged them out of hedges and made them run.
It was always gonna be elecs that got me but there is no more to do ?

Will find a garage somewhere to do this. Need a trailer as clearly won't make the 12 miles to garage on battery alone.

Thanks for help but I was beaten. All because I put the neg wire from reg on the POS battery terminal and rode 1mile . Remember it was fine for years before this one act !,

If garage fix I'll update but we all have done all that can be done

 

[ukjules]

Oh and did this test :

also need to do AC voltage check at 5000 rpm between A to ground, B to ground, and C to ground,
looking for very low AC voltage numbers.​

Result 0 ac volts on all.​

 

[ukjules]

I'm.begining to think i.must have the wires wrong .
Can anyone tell me what the two other wires on the regulator do and go ?
Pic below.
Black and red (I think )


I have one to the loom which has 12v at all times the red one and a black wire to negative battery terminal .
The three yellow to stator

 

[ukjules]

Tell.me.this internet diag is right !! As this is how.mine is. Not.my stator but same connections

 

[tom203]

Yes, that’s correct.
Getting back to basics, does this new stator have same number of poles as the your old burnt stator? 18?

 

[ukjules]

Edit - 18 on original (one on when issue happened ) pic attached
One in bike now , no idea as now in. May ask m&p if they can tell me .

Iv given up. I can't do this anymore.
Can't afford to take to garage now so I'm mothballing it and back on GSX 250 using the shared battery.

Never known a thing like this .
GSX250 running fine with battery off GS and reg I tested on GS

Weather good too so it's 250 rides for me only

 

[ukjules]

Q ) can you put in a stator upside down ? I can't see that I have as wires wouod not reach.

In my stator pic is the facing face of stator facing in or out installing ?
I can't remember on the original

Edit - I don't think it's possible to install incorrectly or wires wouldn't fit. But for info the facing in pic goes into the outside casing.... Wire ag bottom so can be routed . So on bike the face on the floor goes inside rotor ....

But whatever iv given up. Iv changed everything and it doesn't work

 

[ukjules]

Even though given up ... I am gonna -

Just to check on another bike all the tests I did on the 550 on my perfectly working GSX.
This as I am yet to see test results from a perfectly working bike.

Let's see what the actual volt output is on the GSX and all the others. If this shows 50-60ac volts I am sure the stator is at fault .

Will update
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[ukjules]

Ok I have made a document of all the tests I have done on a perfectly working bike (GSX 250) (charging wise) in a logical format using the same.battery.
This for the stator and RR.
Any iv missed do inform.
Remember I am the worst at electrics on earth but I can be logical sometimes.

I'll attach and let all digest and agree that these are working results ......

Next i will send the same for the 550GS that will not charge.

Of course now I can't even attach as the site won't let me upload it . I'll have take a picture and reduce size to send . I despair

Edit - attached

 

[ukjules]

And for regulator:

Comments welcome while I sort same for GS 550 the offending bike

 

[pdqford]

Good job describing all those tests and the results on the charging bike.
I anxiously await your test results on the non-charging bike!

 

[ukjules]

Will do all tests again on non working bike (550 GS) tomorrow first thing (UK time) and post for alls weekend analysis.
​I have old tests but let's do this one more time and compare.
Ill say no more as this is a mid issue revamp.
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