Strange Electrical problem

[mrbill5491]

Coming back from a ride Monday I noticed my lights were dimming badly, the fuel gauge was slowly heading towards E and the my gear indicator was dimming as well. I stopped the bike and checked the headlites, they were barely on. It almost seemed like something was draining my charge. I eventually flipped off the lights and everything came back to life. It was getting dark so I had to leave my bike at a friends house. I noticed the left hand switch was acting a bit funny. I started the bike back up and flipped on the switch and everything looked normal again even the headlites. Though I didn't risk it and left the bike at my friends. As soon as I can I'll check the stator though I'm thinking that isn't it. Something tells me the switch might have crapped out? What say you GSRs.

[posplayr]

Quick Test; show your work.

[mrbill5491]

Quick Test; show your work.

Yup as soon as I can get my bike over to my shop. Gotta make sure the battery is fully charged first before I do anything. Being that it is an AGM it shouldn't take much.

[GSXR7ED]

Hey Bill,

I hope you figure out the problem. You're bike is very well maintained so I'm wondering what the issue is.


Ed

[mrbill5491]

Hey Bill,

I hope you figure out the problem. You're bike is very well maintained so I'm wondering what the issue is.


Ed

Yeah me too, was gonna go get it today, but my friend had flood out at her place yesterday evening, not sure I can get to it just yet. It didn't seem like a charging problem though. More like an excessive draw somewhere.

[geol]

MrBill, You mentioned your left handlebar switch was acting funny. What does that mean? Why was the switch acting out of the ordinary?

[mrbill5491]

MrBill, You mentioned your left handlebar switch was acting funny. What does that mean? Why was the switch acting out of the ordinary?

The hi/lo switch seemed loose or something inside. Remember it is 36 years old. Could have fell apart inside, I won't know until I get the bike to my work shop yet.

[mrbill5491]

Quick Test; show your work.

Okay, here are the results from the quick test

#1 12.8
#2 12.3
#3 12.17
#4 12.16
#5 12.16
#6 12.5

Did a stator test, nada, 1.4-2.3 AC volts (should be around 75-80 AC volts), looks like the stator crapped out.

When the charging system was working I would get a steady 14.5 or so charging then it would regulate down to about 13.8 in that area. Checked all the wiring and connections, nothing burnt or loose, all nice and clean and tight. Even the stator wires to the RR we fine, nothing burnt. Battery came right up and seems to be holding at the 12.8 with the key off.
I'm thinking my CompuFire RR is fine, just the stator gave up the ghost, It is an Electropsort too. So, recommendations?

[posplayr]

How long did that stator run with a shunt. R/R if ever?

if never then it should not be burnt. You will need to post pictures of the stator after the cover is off.

look for other mechanical damage.

[OldVet66]

I ran a marginal stator for a year with my Compu-Fire before it gave up. Put in a new ElectroSport stator and have been running it for years without trouble.

[mrbill5491]

How long did that stator run with a shunt. R/R if ever?

if never then it should not be burnt. You will need to post pictures of the stator after the cover is off.

look for other mechanical damage.

This stator was installed new with the new Compufire. Think it is around 8 years old since I did the change over.

It is gonna be a few days before I can get the cover off. I'll post when I do.

[posplayr]

This stator was installed new with the new Compufire. Think it is around 8 years old since I did the change over.

It is gonna be a few days before I can get the cover off. I'll post when I do.

I will be very interested. I theorized a while back that now that we have long term series R/Rs in operation where the stators are not burned to a crisp is short order, other design flaws in stators will probably come to the fore front that were not possible before.

I would look for indications of mechanical fatigue due to flexing of the winding. This is where the heavy epoxy coatings on the winding comes into play.

[mrbill5491]

I will be very interested. I theorized a while back that now that we have long term series R/Rs in operation where the stators are not burned to a crisp is short order, other design flaws in stators will probably come to the fore front that were not possible before.

I would look for indications of mechanical fatigue due to flexing of the winding. This is where the heavy epoxy coatings on the winding comes into play.

I'm curious as hell too, I want to know what happened. Just a note, two weekends ago I did do that 1000 mile ride and don't think I ever flogged that bike that hard before. Trying to keep up with our State Police escort was fun as hell though. Did see some 100+mph in places. Cool cops huh.

[GSXR7ED]

I'm curious as hell too, I want to know what happened. Just a note, two weekends ago I did do that 1000 mile ride and don't think I ever flogged that bike that hard before. Trying to keep up with our State Police escort was fun as hell though. Did see some 100+mph in places. Cool cops huh.

1000 miles!!??

That's quite the ride compared to the 275 mile jaunt we did on the only group ride I've ever done in NM or in my riding life.

We hit some good speeds too...as I recall.

Very interested in your investigation.


Ed

[mrbill5491]

I was looking at stators, Caltric stator for my bike is $45?? what kind of quality am I looking at here. One on Z1 is $132 and Rick's stators are $139. ElectroSport is $119