Caltric stator fail

[Greg7]

Just finished installing a new Caltric stator and took the bike for a quick spin.

Everything seemed fine until I got up to a stop at a traffic light. I heard what almost sounded like a bolt rattling around in the left side case. Only lasted for about 3 seconds.

Turned bike around and as soon as I pulled in the driveway and put it in neutral it made the same noise again.

Took the left side cover off and found shreds of metal stuck all over the stator and rotor. Gouged the magnets pretty bad.

I'm guessing the stator was slightly larger in diameter that the old one even though when I checked it against the old one it appeared to be similar in size? I did notice a little resistance when putting it all back together but due to my inexperience and lack of patience I just thought it was resistance from the magnet. When I started it up initially nothing sounded abnormal at all.

Not sure what to do now as far as getting all the metal out and be mad that I was impatient and cheaped out on the part just so I could finally start riding again. Stupid expensive mistake.

I'll attach some photos for your viewing pleasure

[Greg7]

Here's the stator. IMG_20200512_224811892~2.jpg

[RedBaron]

I can't comment on their quality in GS machines, but I had a customer bring me 3 for a DRZ400 before one finally functioned. I'm unsure what's currently in my GS. Probably a Rick's if they made one. Always had decent luck out of their stuff in customer units so it's either that or another stock one from my parts bike.

I'm unsure which GS you're dealing with but on mine the oil pan was reasonably easy to remove and clean, as well as the strainer it covers.

[Greg7]

I can't comment on their quality in GS machines, but I had a customer bring me 3 for a DRZ400 before one finally functioned. I'm unsure what's currently in my GS. Probably a Rick's if they made one. Always had decent luck out of their stuff in customer units so it's either that or another stock one from my parts bike.

I'm unsure which GS you're dealing with but on mine the oil pan was reasonably easy to remove and clean, as well as the strainer it covers.

It's an 82 gs1100gl. Hoping since it's mainly the magnet poles on the rotor that got gouged that most of it stayed inside the left casing. Being a magnet and all. Looks like now I'm in the market for a new stator again and a rotor unfortunately. So far all I have found rotor wise is apparently only compatible with chain driven models not shaft driven.

[Gorminrider]

Huh! that's very sad...it's odd that one just one magnet is severely gouged? If the stator were oversized or out of round I'd expect it to rub the whole magnet....and

I heard what almost sounded like a bolt rattling around in the left side case.

...looks like there was something stuck to the magnet or the stator that got in the airspace?

[93Bandit]

Huh! that's very sad...it's odd that one just one magnet is severely gouged? If the stator were oversized or out of round I'd expect it to rub the whole magnet....and ...looks like there was something stuck to the magnet or the stator that got in the airspace?

This is what I thought as well. I suspect the Caltric stator is not at fault, rather there was something stuck to the magnet when you installed the new stator, creating the resistance you felt.

[Greg7]

That also seems more likely to me. Haven't come across any missing bolts or sockets that could have been the culprit....yet anyway. There's more than one magnet gouged but not all of them. I'll post more pics but for whatever reason I can only add one per reply.IMG_20200512_221044884~2.jpg

[Greg7]

Here's another of the statorIMG_20200512_224729367~2.jpg

[LAB3]

No matter what the cause that's just plain ugly to see. My condolences to your wallet.

[Gorminrider]

agree with that^^ ! it's really Bad luck for sure... it could be something very small that was trapped in the windings from the stator factory or some little thing from your bench....totally pulverised-it might not even have been steel....

Still, your stator windings look ok and the magnets, though ugly, are still magnets. I'm suprised they didn't rip off and shatter! ...You might just be able to change the oil(!) ,clean it up, slap it together and carry on awhile?

[Rich82GS750TZ]

Still, your stator windings look ok ....... ,clean it up, slap it together and carry on awhile?

I don't know. That pic of the stator in post #2 would not inspire me to reinstall it.

[Greg7]

Yeah if anything I will just keep it as a paperweight. I'm going to clean it all out and go for round number 2 with a new stator. Can't seem to find a replacement rotor at the moment though.

I don't know. That pic of the stator in post #2 would not inspire me to reinstall it.

[Steve]

In my opinion (for what that's worth), you did not "cheap out" on the stator.

I have installed several Caltric stators, all with good results.
Like any other stator, they will last a LOT longer if you also install an SH775 R/R.

Yeah, a different R/R would not have saved your stator from that damage, but I agree that there must have been something stuck in there when you installed the new stator.

.

[Rich82GS750TZ]

Don't remember how or why, but I seem to remember buying a box of GS parts years ago. In that box is a rotor with starter clutch attached. No idea what model it's for or how many poles. Here are some pics. It's missing 1 of the 3 springs in the back of the clutch maybe something else in there. If you can use it, you can have it for shipping cost.

[Rob S.]

Remind us of your year and model. Maybe put it in your signature.