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Rode without a rectifier. What should I do?

Started by tzzzel, November 11, 2015, 03:00:10 AM

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tzzzel

Hi everyone. Having electrical system issues. My 2nd to last rectifer went bad... saw burn marks on the connectors. So I bought another one on ebay. That one didn't give me proper charging voltage from the start and last week when I tested it, it was only outputting maybe 12.3v @5000 rpm. Not sure if it's my system or a faulty rectifier (it was used). SO, I took off the rectifier and ordered a new one off ebay.

Rode my bike 2x since then. I only ride in town, about max 35 mph, and almost never go over 4k rpm. However, I read that riding without a rectifier can cause the stator issues. So, I don't want to mess around and possibly start a fire or damage wires. What should I do to keep my bike good and safe? I'm guessing replace the stator?
2004 GS500F owner and lovin' my low insurance premium, air-cooled ride. Design and develop websites for a living. Previously owned a 1999 Ninja 500R.

The Buddha

If you're on your 3rd rectifier, I'd say your stator is long dead.
Look at it, if it looks nice and golden bronze - it is OK, if it looks black and burnt its dead. Even in 1 spot burnt = bad.
Cool.
Buddha.
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tzzzel

Cool. Thanks. I just ordered a stator as a precaution from ebay for about $40.

Will be changing out the stator, rectifier, and giving it an oil change. Hopefully this should mean smooth sailing for a while.
2004 GS500F owner and lovin' my low insurance premium, air-cooled ride. Design and develop websites for a living. Previously owned a 1999 Ninja 500R.

Big Rich

Check your connections as well. I don'thave a wiring diagram in front of me, but a bad ground somewhere can cook your system. 
83 GR650 (riding / rolling project)

It's opener there in the wide open air...

tzzzel

I finally got my parts in the mail (new stator, new gasket, new rectifier).

However, I popped open the crankcase and to my surprise... the stator was looking fine.

http://imgur.com/a/y7T2f

See above pics. I was expecting it to be fried from both my charging system not going well and because I had ridden with a rectifier attached for a bit. As it turns out, all the copper looks fine. You might see a little darkness in the pics, but that's just the glue on the coil that's dark -- the coil itself is fine (I turned it over and checked). So, that was a surprise.

I went ahead and changed my oil and attached my rectifier (new, used off ebay), not wanting to replace a good looking stator. I also did the multimeter OHM test and everything looked ok. Here are my approximate readings:

semi-charged battery at rest: 12.15v
key in on state: 12.00v
turned on, idle: 11.5v
revved @ 5k rpm: 12.5, with a jump to 12.65v after releasing thottle

I'm not sure how things will go from here. My readings are a bit off, but hopefully, that is from a less-than-full charged battery and doing some riding will put it back up to normal voltage. We'll have to see.

If you folks have any other insights, I'd greatly appreciate it.

PS: when I took off the crank case, I saw this orange solid stuff around the cylindrical magnet thing. But parts of it was broken. You can see this in the picture. Should I be concerned?
2004 GS500F owner and lovin' my low insurance premium, air-cooled ride. Design and develop websites for a living. Previously owned a 1999 Ninja 500R.

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