supra5677
Pro
Posts: 1279
|
posted June 05, 2006 09:01 AM
stator problem
My friend has an 01 ZX12r with akra and pc3r.. He has been having stator/charging problems since he's had the bike.. His first stator was burning the coils pretty bad so he bought a used but good stator. This was last year.. He does have a rigged non stock connector that goes to his stator.. It looks like someone rigged it, it is not the stock round connector.. Yesterday he started having charging issues again.. I think he has a direct short in the harness or something.. Can somebody help?
supra
   
|
Y2KZX12R
Needs a job
CompetitionCNC.com
Posts: 3762
|
posted June 05, 2006 09:56 AM
When I get home i can look up the resistance in each stator coil for ya so you can check it for opens and shorts.
Some people had issues with those connectors melting. And of course the famous oil leakage from the connector caused by the ram air system. You should seperate the crank case vent from the airbox (ramair). The ramair pressure has to be overcome by the crank case pressure to get any positive flow past the reed valves in the crankcase. By seperating the two you alow the crankcase pressure to always open the reeds and escape.
Just cut the vent tube and block off the airbox end and put a k&n on the crankcase end. Dont bother with hooking up the crankcase vent to the kleenair system. Theres nowhere enough suction or volume of suction to even think about evacuating the crankcase. Besides, you will get far more bennifit from letting the header scaveng the combustion chamber thru the exhaust valves anyway.
____________
Y2KZX12R
CompetitionCNC.com
|
five 0
Expert Class
Posts: 215
|
posted June 05, 2006 11:23 AM
Could have a wiring problem. I modify alot of harnesses for these dirt cars and I see alot of older ones that have some pretty hot looking white wires. I have alot of used parts also if he needs anything. What about the rectifier?? Could it be doing it??
5-0
|
Y2KZX12R
Needs a job
CompetitionCNC.com
Posts: 3762
|
posted June 05, 2006 01:06 PM
 Edited By: Y2KZX12R on 5 Jun 2006 14:14
stator ohms are .3 to .5
when running each leg should put out 85-120 volts ac across each pair (3) at 4000 rpm
and the regulator/rectifier output volts are 14.2-15.2 dc
____________
Y2KZX12R
CompetitionCNC.com
|
supra5677
Pro
Posts: 1279
|
posted June 05, 2006 01:11 PM
thanks I'll pass it on
|
Megabyte
Pro
Posts: 1047
|
posted June 05, 2006 03:29 PM
Alot of guys swear by the crankcase vent mod. I didn't do a before and after, but my 1361 makes 212 rwhp with the crankcase vent mod. I do have a few other mods of course 
quote:
When I get home i can look up the resistance in each stator coil for ya so you can check it for opens and shorts.
Some people had issues with those connectors melting. And of course the famous oil leakage from the connector caused by the ram air system. You should seperate the crank case vent from the airbox (ramair). The ramair pressure has to be overcome by the crank case pressure to get any positive flow past the reed valves in the crankcase. By seperating the two you alow the crankcase pressure to always open the reeds and escape.
Just cut the vent tube and block off the airbox end and put a k&n on the crankcase end. Dont bother with hooking up the crankcase vent to the kleenair system. Theres nowhere enough suction or volume of suction to even think about evacuating the crankcase. Besides, you will get far more bennifit from letting the header scaveng the combustion chamber thru the exhaust valves anyway.
____________
We First make our habits and then our habits make us.
|
supra5677
Pro
Posts: 1279
|
posted June 18, 2006 07:10 PM
ok my buddies stator is burned up and bad.. This is the second stator that has gone bad on him.. He's talking about buying a Hayabusa! Not good. Somebody please help..Could it be the rectifier? He does have 1 plug that goes into the rectifier replaced with another plug.. But something in the last 12 months is making his stator go out.. If he replaces the harness, rectifier, and stator will that fix it?
supra
|
park12r
Expert Class
Posts: 124
|
posted June 18, 2006 08:26 PM
Edited By: park12r on 18 Jun 2006 21:28
that is happening to me now...2nd stator burn/melt... i join them direct n solder them up... im running with block off plates so i wasnt keen about the crank case mod...now knowing about this knN filter mod..i will go for it...
|
ridgeracer
Pro
Posts: 1309
|
posted June 19, 2006 06:29 AM
Supra how is the stator bad? Shorted? Open circuit?
There is nothing special about a stator, it is just a bunch of copper wire wrapped around laminated iron pole pieces. The efficiency of the coil increase the more windings you pack into a given area. For that reason the copper wire is not insulated with a thick vinyl coating like the harness wire but is simply 'varnished'. Over time, years and years, the vibration and heat can cause the varnish to rub away and cause a short in a coil. Opens usually occur at junction points where the coils connect together or to the ouput wires. Obviously this should not happen in a year.
The other way to destroy a stator is to overload it. The more current it conducts the hotter is gets. Too much heat causes the varnish to break down much faster and eventually leads to a short. The fact the alternator plug was replaced indicates to me a previous stator also was overloaded and the heavy current going through the plug probably melted it. You stated he had a PCIII so obviously the wiring harness is not totally stock.
It is unlikely to be the rectifier. None of its failure modes is likely to lead to a short across the stator and any that did would have so destroyed the rectifier that putting in just a new stator would not fix the problem. I would also expect the regulator to be current limited so that it would shut down if it noticed a dead short across the 12V power.
I suspect that who ever installed the PCIII did not route or insulate some of the wires correctly or moved other wires where they could get pinched or worn through and caused a condition that intermittently shorts to ground. I would carefully inspect every inch of wire harness for rub through marks or exposed wiring or discolored wire. I would start at the alternator plug and inspect the yellow wires to the rectifier first. Also there is a white wire that leads from the alternator to the Junction Box Headlight relay
Good luck
|
supra5677
Pro
Posts: 1279
|
posted June 19, 2006 01:45 PM
its kind of hard to screw up plugging in the power commander.. One wire to the ground on the battery and the rest directly plugs in...Looks like my other buddy with a busa and my buddy with the 12r are going to switch bikes.. My buddy with the 12r loves the bike but doesnt have the money to deal with it, and my other friend is tired of being whipped by 12r's we'll see..
|
|
|
HOME
NEW TOPIC