Battery not charging

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Sep 19, 2012 | 07:23 AM

#31

cHarley

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Joined: Feb 2007

Posts: 16,320

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From: Boynton Beach, FloriDuh

Quote:

Originally Posted by gilmour68

This one had me scratching my head all day until I actually removed the stator from the case. Last night it checked ok with an ohmmeter and I was second guessing the decision to buy a replacement. When I pushed the wire thru, I found that one of the wires had burned and separated from the coil. Just like last time, but in a different spot that wasn't as obvious. The burned lead explains the dark oil, smell and charging issue.

The Cycle Electric parts looked great and they arrived only two business days after I ordered them. Great, fast service!! Probably due to my past experience, I was able to pull the stator wire thru the labryinth fairly easily and I had everything installer much quicker than last time.

I put the clutch pack and drive gears on and left the primary cover / clutch can wait till tomorrow. Guess I'll be contacting Accel about their warranty.

1 - That's why I believe it's best to check the stator output with the bike running, before I disassemble things. Ohms tests on a bench are fine to pre-check a new part before installing it, but checking the stators output with the motor running is pretty much a Go - No Go deal test of the complete stator assembly, checking the rotor and magnets at the same time.

2 - All three of my stator failures had the wire broken off at the same place. That's wire fatigue from vibration. Notice on the new Cycle Electric stator how the area where the wires leave the coil is protected/supported with the gray potting material and the wire gauge is heavier.