Stator and wiring burn out ? - GS 550et 1980

[ukjules]

Unfortunately I can no longer post images on this site. No idea what's happening but the site is so hard to use on a mobile.

So I can't send proper wiring diagrams.

The bike now sits waiting for someone to tell me how on earth I voltage drop check the loom from the regulator which seems to be the issue

[tom203]

Let’s back up a bit…..
slayer asked…”Do I understand you correctly that you ran the bike until it got warm with the 3 stator wires shorted together and held to ground (earth)?”

Did you just miss type?
Your regulator is proven ok…based on other bike. But no stator output, so it seem this stator is cooked….or maybe stator leads got pinched on stator cover during installation. I’d remove the 3 stator leads from r/r and check all three for a grounding out on motor….but this isn’t very conclusive, since when bike runs there are magnetic forces tugging at stator windings in their slots,

[ukjules]

I didn't miss it as I never said that .
All stats are available on thread.

We are down to wiring

[ukjules]

Bike to a bike garage as this is beyond me.
Iv replaced the entire charging system and still it will not charge.
Every possible test on the regulator and stator has been done. Fuses ok. Battery ok.

So it has to be the wiring or an incredible coincidence that the new stator is faulty in some way.

So wiring I simply have no idea what to check and results I posted to a question on here point that this is the fault .

Where this fault is in the wiring is beyond me thus to a garage .

In all my years iv never had a problem like this . Fixing charging issues is usually simple !

Anyway bike stored and be a few weeks for garage too look at it.

[slayer61]

I didn't miss it as I never said that .
All stats are available on thread.

We are down to wiring

From post 6 in this same thread...

Status of as was with old stator :
- when bike cold two tests seemed to show it to be ok. It failed when I had warmed bike up on 3 wires to earth.
- checking regulator it tested ok This testing with the diode setting on MM.

Sorry Jules. I thought you really ran the bike with the 3 stator wires shorted together and to ground based on the above statement.

[ukjules]

Ok current status : I send so all know what happened and status.

I went away for a few months , returned. Bike was sat with neg terminal off battery. So I put back for a ride but I made the mistake of wiring the neg earth of the regulator to the POS terminal of the battery.
3 yellow leads were corrected correctly and pos output lead was correct to loom.
I ride one mile and bike just died.
Since then bike has never been able to charge.

Anyway I realised my mistake on roadside and managed to bump bike to get back after bodging 3 stator wires and earthing reg wire properly.

- repaired the 3 yellow stator wires that had fried
Still no charging.
- added new stator
still no charging
- added regulator from GSX that works and charges
Still no charging
-Bought new regulator for bike
Still no charging

Fuses ok , Battery known to work and charge on GSX, Bike ok in every other way.
Bike ran perfectly before this incident

[ukjules]

As now have a bag of regulators though I'd test them for charging on GSX.
Original - this on when charging system blow up. On GSX this one shows battery charging at 16v ! Clearly not good

GSX original one - reg works fine
New reg for GS - works fine

So I know I have a working regulator (or a few ) for the GS.

Stator or wiring (it is so unlikely that a brand new stator is faulty it has to be the wiring but that stops me dead hence to a garage in a few weeks)

[ukjules]

Update :
New stator confirmed to be faulty after running bike test attached. I took a risk at buying a cheap one which has not paid off and threw me down a rabbit hole.

Beware anyone who assumes that a bench test with bike not running is 100% confirmation of a working stator !! Mine tested fine in those tests !

New regulator Def works fine as tested on another bike - GSX

Asked for a swap out stator as this one faulty.

[slayer61]

Congratulations on getting it sorted Jules. Well done. Perseverance pays off in the end

[ukjules]

But hold on ........
Yes faulty stator being sent off today and replacement being sent to me. We can only be sure when I see charging happening !!!

But imagine if this 2nd new stator passes all tests but doesn't charge the bike ......
It can't be the regulator, battery , fuses .......

But let's hope ! Will update. But my mistake mush have blown the original stator and regulator. Not much else to blow ?

Will update !

[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.