Thanks for the in depth explanation of what you did to diagnose the problem. I am sure it will help a lot in the future.

Motorcycle stators are a common problem part. They were dreadful on Suzukis in the 70s and 80s, and they are still a problem for everyone. If you think about what they are, you can see how they would be. They have a lot of fine windings, all insulated, but bathed in very hot motor oil. They are subject to extreme thermal stresses from heating and cooling. Copper expands a fair amount when it heats up, so each thread of a stator coil gets somewhat longer every time your engine warms up and then shrinks when it cools back down. Add in the variance in temperature due to motion/the fan coming on/etc. and it is a lot of movement for the insulation and connections to handle. It is much worse on air cooled bikes, but water cooled bikes are not immune to problems.

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Will
It's a squid thing. You wouldn't understand.

this the info from custom rewind where i got mine rewound. Works great and decent price too. $85! very happy with them.
To better serve our customers, we have found the best method of

communication, for us and the customer is by phone.

For product information, availability, and pricing.

Please call us @ 1-800-798-7282

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pretty quick turn around too.

Hi Guy's, If your charging system is faulty do any of the warning lights show? Just that the S4 is playing up a bit at the moment ( I think it's a faulty battery ) I tried to start it up today and got a click and the gauges went blank, Waited a while then the gauges came back pressed the starter got an audible click and they went blank again. I put jumper cables to a jumper battery and she fired up. Not sure if this is charging related or just a poked battery.

Basically, if your battery is charged and you go riding, and while your riding your gauges start flashing and eventually go blank. Something is probably at fault in your charging system. But of course always test that battery first. Again: Charge the battery (on a 1-2 amp charge) till its got 13.3-13.5 volts. Let it sit after that for 30 minutes to an hour, then test the voltage. It should still be pretty close. If its below 12.5 its a junk battery.

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Cheers Red, Will test tonight.

Test results Ok, 12.72v standing, drops to about 11.2 starting then runs to 14.35v at 1500 rpm. Filed all the connections. Will try it again in the weekend when I have a bit more time to see if it shuts down again ( I really hate intermitant faults ) But at the mo all seems well, starting as normal. STRANGE!!!!

put the new one in, this time actually new, from electrix world in the uk. I havent done any official tests to find out if all is well, but it seemed to be running great. Hopefully it wont snow anymore this weekend..

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so it seems that while riding my speedo background light flickers but it has yet to fail. I replaced my battery a couple months back, So I assume thats not the cause. By reading I assume I should check the red-wire contact on the rectifier/regulator connector also has a history of oxidation/corrosion. Be sure to check these, clean them and use new dielectric grease! but I dont know exactly where this is. If anyone has pics I would appreciate it. It "feels" like a loose connection but I am coming up on 24000 miles (maybe the stator(I hope not).... to test stator would I be using this wire



I had to steal this pic from ebay but I guess it should work

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Matt
2001 Racing Yellow TT600
Be an Individual... Be a One-Off.

yeah thats exactly it for the stator.

for the rectifier I cant remember off hand. If you take off your seat the rectifier is mounted the the frame on the left side. It has cooling fins. Actually now I remember, you remove the tail piece on that side (very easy to do just those white plastic pins and maybe a bolt) Then you have complete access to the rectifier. I dont remember where its connection goes though

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