Need Stator Help QUICK! Sunday afternoon.

[Tourmeister]

Howdy,

So we are in the middle of swapping out a motor. The original motor (2001 model) has a plug on the end of the three yellow wires coming from the stator. The matching plug has three black wires. This makes me think that it does not matter which yellow wire mates with which black wire. However, the motor we are installing (a 2000 model) does not have the plug on the end of the three wires. It has three separate plugs, one for each wire. All three wires are yellow as on the 2001 motor. My question is does it really matter which yellow wire attaches to which black wire or are they all going the same place? We were going to swap the wires and stator winding but one of the screws holding the wires in place is badly stripped and we can't get it out.

Any help would be very much appreciated!

Adios,

[starwalt]

The stator windings and the rotor make a three phase AC generator. Mixing up the wires would mess up the "rotation cycle" of the three phases A,B,C. In the electrical power world it may or may not matter depending on what the phases are connected to.

Would this mess up the regulator/rectifier in our application?

Looking at the Clymer manual, page 261, a simplified version of the charge circuit is shown. My guess is that it DOES matter because the SCRs (Silicon Controlled Rectifiers) are probably turned on in sequence as part of the voltage regulator circuitry.

Don't take my opinion as the last word. Let's hope someone else chimes in here with a Suzuki factory manual that may break it down more. Let's also hope someone else has done this before.

[sprint_9]

I would take the time to get them connected to the right wire, I believe it does make a difference where you connect them and if you dont get it right you could likely ruin more parts on your bike.

[Tourmeister]

Well, thanks for the feedback. I managed to get the wires from the 2001 motor out and swap them with the 2000 motor (the one we're installing) and everything works great. The engine fired right up! Now we just need to get the bike sold so my friend can get the SV650S she has been lusting after for some time now  :lol:

Adios,

[John Bates]

..................... My question is does it really matter which yellow wire attaches to which black wire or are they all going the same place? .............................

Not knowing, you did the cautious thing.

However, it doesn't matter how they are connected.

The regulator control ckt doesn't know the position of the rotor. It only knows the voltage at the output and adjusts all three phases at the same time.

The three positive rectifier diodes lead to the same place as do the three negative rectifier  diodes, "all roads lead to Rome" as they say.

[starwalt]

Glad to hear the good news Scott!  

Well John, what you said was going to be part of my original reply.  :lol: If the schematic had shown all three SCR gates tied together, I would have said it didn't matter because one control signal changed all phases. I advised on the side of caution until more data came in.

I have been burned before with partial schematics and am always wary of third party drawings until I have proved them OK. Of course these manuals and bikes have been around for years so the QC feedback should have taken care or errors somewhere after the second edition.

One of my things to do when I get this sucker running is to take waveforms of the signals.  Yes, I am anal that way but 26+ years of electronic/electrical service tends to get one stuck in a mindset.

That's why I decided to tinker with motorbikes! Paradign shift!  :lol:

[John Bates]

.............. Yes, I am anal that way but 26+ years of electronic/electrical service tends to get one stuck in a mindset.

Yeh, but it's a lot of fun.