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The charging curse strikes .... again

HTML: 
So you have had no failures either, other than buying dead ones?
No I haven't had any problems since doing the repairs other than the stator replacement a year after installing the Compu-Fire. I attribute that to ignoring good advice on the forum, that said the dark color of the old stator was not normal and would fail, even though it tested good at the time. I didn't have a Megger to test the insulation varnish and sure enough it failed. I used the Furukawa RFW single waterproof connectors on the stator leads.
 
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My stator (likely the original) failed at 38k- the replacement (used off an 81) sorta failed at 42k. I was still messing with things electrical at this point. I put the SH-775 on with another 81 stator- so far so good, but I have backup stators still and then there's Steve's guy!
I feel Shindengen has torture tested this unit, but you guys in the hot climates will find out.
 
A prod with the DVM reveals a winding short to ground. One of the connectors has also developed a heated look to it. Damn, blast and soddit; I had checked, cleaned and repaired this less than a year ago. Ho-hum...
Another prod revealed the stator on the parts engine has a winding short to ground, too.
Means I'm down to two spare stators and they're both old.
I'll get an SH-775 as a first measure and see how one of the old stators holds up, but will acquire a new stator to fit sometime soon.
 
Grimly said:
Means I'm down to two spare stators and they're both old.
I'll get an SH-775 as a first measure and see how one of the old stators holds up, but will acquire a new stator to fit sometime soon.
Click to expand...
More cores for Steve.
 
I've never had a stator on a GS go out on me, nor an R/R. Interestingly, whenever I tested the voltage at the battery, I never tested one that had the voltage that it was supposed to. 100% of the cases were not charging correctly. In every case but one, I was able to make it charge correctly by cleaaning / eliminating connectors, adding grounds, and usually putting a used GL500 or GL1000 R/R. All the systems I checked, about 10 or 12, had marginal charging, like 13.3 or so volts. There were no symptoms in the way the bikes operated. More often than not, there were visibly overheated connectors on the wiring loom, generally the three stator wire connectors and the big red R/R output wire. If you check your charging system for the first time, I bet that you will be surprised.
 
850 Combat said:
I've never had a stator on a GS go out on me, nor an R/R. Interestingly, whenever I tested the voltage at the battery, I never tested one that had the voltage that it was supposed to. 100% of the cases were not charging correctly. In every case but one, I was able to make it charge correctly by cleaaning / eliminating connectors, adding grounds, and usually putting a used GL500 or GL1000 R/R. All the systems I checked, about 10 or 12, had marginal charging, like 13.3 or so volts. There were no symptoms in the way the bikes operated. More often than not, there were visibly overheated connectors on the wiring loom, generally the three stator wire connectors and the big red R/R output wire. If you check your charging system for the first time, I bet that you will be surprised.
Click to expand...

It can very well be the case. My first bike was an 1981 GS750E, that I had just purchased and ran fine except the PO said, "the bike probably needs a new battery".

After reading the electrical section here, I went to inspect the bike. The battery was over charged and boiled dry and the ground wires cooked (see picture below). After cleaning connections and adding grounds full operation was restored. Those wires to the ring lugs are bare copper with every bit of insulation burned off. I opened up the wrap on the harness to find the B/W common pint in the harness. It was obvious from the heating pattern that there was mucho current flowing between the two ground ring lungs and not running through the harness.

picture.php
 
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