A thorough stator repair process should include all of these steps:
- Test the defective stator upon reception.
- Re-insulate the stator core with heat resistant epoxy.
- Rewind the faulty coils with heat resistant wire while paying attention to any known problems.
- Secure the wiring by soldering it.
- Varnish the stator to ensure there is no possible short circuit.
- Heat the varnish to strengthen it.
- Test the repaired stator.
What are some symptoms of a bad stator?
- Hard starting: Hard starting when cold or won’t start when cold
- Hard Starting: It starts good when cold but starts hard after it has been ridden and it’s warm or won’t start at all when warm.
- After it warmed up it won’t start but if it sits for an hour it’ll start again
- No spark. ...
How does a motor act with a bad stator?
The stator coil generates the power for the spark plug and other accessories on small engines Without a stator there would be no spark at all, meaning the engine won't run. While a stator is dying, it can produce a weak spark, causing the engine to miss or run poorly. Symptoms are often worsened as the engine warms up.
How to rewind a stator?
To rewind an electric motor, remove the motor's outer housing and use your hands to pull the armature out of the stator. Then, use a flat head screwdriver to pry open the tabs on the brush pads, and then cut through the wires and pull them out by hand.
Can you fix a stator?
Stators come with a wire harness, rubber grommets, and all end connectors for a more tech friendly installation whenever possible. Repairing malfunctioning stators may be a way of saving money and often a viable option for faulty stators that have been discontinued from the manufacturer or unobtainable as a new part.
Can a stator just stop working?
Your stator will wear out over time. Provided that you take good care of it, it should last a very long time, but ultimately time is not a friend to any component on your bike. The other main cause for your stator failing on you is a power overload. This can happen when you run too many accessories at the same time.
What causes a stator to fail?
When a stator fails, it is largely due to the degradation or aging of its insulation through external occurrences and materials being introduced into its system.
What happens when a stator fails?
This happens when the battery is trying to draw current from the alternator, even though it's not providing any power. No start: Finally, a bad stator can also cause the bike to not start at all. This is because the alternator isn't generating any power to run the engine.
How do you troubleshoot a stator?
1:163:32#1 How to test a motorcycle stator - YouTubeYouTubeStart of suggested clipEnd of suggested clipOkay what we're going to do is look for continuity. Between all three phases and make sure nothingMoreOkay what we're going to do is look for continuity. Between all three phases and make sure nothing goes to ground using your service manual you're going to locate.
How do you bypass a stator?
3:246:32Jumper Wire Electrical Bypass Testing and wiring harness to key 1990's ...YouTubeStart of suggested clipEnd of suggested clipSo what you do to bypass your wiring harness is directly wire your key. Directly why are your keyMoreSo what you do to bypass your wiring harness is directly wire your key. Directly why are your key right into the cable coming from your stator. And you're going to bypass.
Does a stator charge the battery?
An ATV uses what is called a stator system or magneto system to charge its battery. This is a fairly simple and robust system located on the inside of the ATV's engine. Any time the engine is running, the stator is continuously generating an electric charge.
How much does a stator cost?
The Stator is priced at $3,995, though you'll only need to put down $250 to reserve your own Stator. Just try not to think about how that same $250 deposit could buy you an entire Amazon electric scooter.
Will stator cause no spark?
90% of no spark is caused by the CDI Charge Coil in the Stator.
Can you clean a motorcycle stator?
Re: cleaning a stator? I would use electrical contact cleaner on all the electrical parts, flywheel, and inside of the cases. You may need to use some steel wool to remove the rust. As far as the crank seal...
Can a stator be rebuilt?
In many cases a new stator is the safest, most cost-effective solution for an electrical system breakdown. Because repairing stators can be an intricate and detail-intensive process, replacing failed stators with an entirely new part can be a much easier route, depending on the specific motorcycle.
How do I know if my stator is working?
2:463:41How To Test A Trail Tech Stator - YouTubeYouTubeStart of suggested clipEnd of suggested clipIf this stator is in good condition. It should be reading between 0.3. And 0.5 ohms. As you can seeMoreIf this stator is in good condition. It should be reading between 0.3. And 0.5 ohms. As you can see we're right in that range 0.3 point 4 it's perfect.
Why does my stator keep burning out?
That high voltage spike can punch through the enamel insulation in the stator coils and cause them to short out. This “inductor kick” is how the spark in an ignition coil is generated from 12volts. Not many people realize the spark is created when the current through the coil is switched off.
What causes a rectifier to burn out?
Things like poor grounding, a loose or weak battery, and a worn battery connection can all lead to regulator rectifier failure.
How many volts should a stator put out?
For each 1000-rpm, a 32-amp stator should have 18 volts AC (VAC) per it. It should be 36 VAC by 2000.
What is the probable reason for failure in this 3 phase stator winding?
TYPICAL CAUSES OF WINDING FAILURES IN THREE·PHASE STATORS failure is the result of an open power source, a poor the insulation in all phases of in one phase of the power connection at the motor the motor normally is caused supply to the motor.
How does the stator work?
The stator is the coil of wire housed inside the engine case. A magnet on a shaft spins within the stator, creating alternating current (AC). That current travels along fairly heavy gauge wire through the case and into the rectifier/regulator which converts it to DC power, and at a consistent output.
What is a stator coil?
The stator coil generates the power for the spark plug and other accessories on small engines Without a stator there would be no spark at all, meaning the engine won't run. While a stator is dying, it can produce a weak spark, causing the engine to miss or run poorly. Symptoms are often worsened as the engine warms up.
Why does the wiring pass through the engine?
The only reason the wiring passes through the engine is to reach the contact breaker system. The contact breaker is simply a switch inside the flywheel that triggers the spark plug to fire at the right moment in the combustion cycle. The engine is not actually producing any power for the ignition system.
What happens if you put a wire in the wrong place on a contact breaker?
If you put this wire in the wrong place on the contact breaker, it will directly contact the first wire and bypass the switching effect of the system. Without the switching effect of the contact breaker, the spark will never fire.
How to access flywheel on Honda XR?
Here are the steps to gain access: -Remove the side cover over the flywheel. Depending on your model this may be the left or right cover, and may also be holding back oil. On my honda xr, I removed the left side cover to access the flywheel, and it did not hold back any oil. -Remove the flywheel.
Can You Fix a Stator and How to Do It On Your Own?
Replacing stators can be very expensive. The price of a new stator ranges between 350$-600$, and for some motorcycle models, the price can get up to 1600-1700$. This includes the price of the stator only, and added expenses are more when you calculate the job you need to pay to the mechanic.
What Leads to a Stator Malfunction?
There are many possibilities that can lead to stator malfunction. Taking good care of your stator and motorcycle, in general, will make your bike last much longer. Therefore, it will spare you to pay any unnecessary repairs that could occur if you don’t take care of your motorcycle.
Signs of a Bad Motorcycle Stator
So how will you recognize symptoms of a bad motorcycle stator? No spark, poor spark, or misfiring are the most accurate signs that can signal you that you are dealing with a bad motorcycle stator. Other signs that can signal that your stator needs to be repaired or even replaced are difficult engine ignition.
How to Increase Your Stators Lifespan?
There are cases where riders have had stators last them 250 000-300,000 miles. If you get higher amperage, it will cause a shorter life span of your stator. High amperage is one of the biggest causes for stators to malfunction. Taking good care is vital for the stator to last longer.
Conclusion
The stator is responsible for the electrical system’s functionality, and since its purpose is to generate power for your motorcycle electronics, we can say that it is vital for it to function correctly; otherwise, the whole motorcycle is out of use.
New Stators Are Not Readily Available For All Models
Why would anyone go through the hassle of getting a stator repair instead of just replacing it by a brand new one? For starters, not every stator is available for sale. When an OEM discontinues a particular vehicle model, very often they stop manufacturing the replacement parts for that model.
Aftermarket Parts Issues
Have you had issues with an aftermarket stator in the past? Getting a stator repair versus replacing it might be the best solution. Keep in mind, not all aftermarket companies are bad. There are plenty of great manufacturers out there making brand new OEM quality stators that match or improve upon factory stators.
There Are Only Used or Refurbished Stators Available
Another good reason to repair your stator would be if only used stators are available for your particular model. A quality stator repair by a qualified technician will make a used stator good as new.
What is the purpose of a stator?
The stator’s primary job is to recharge your ATV’s battery while it is in use, but many ATVs have stators capable of doing more. Your stator might include one or more of the following:
How much does it cost to replace a stator on an ATV?
Stators aren’t usually expensive for most ATVs. They will usually cost under $100 for the part and can be significantly less.
What is a stator on an ATV?
Stators can look quite different depending on the brand of ATV and model, but in general, they consist of an iron core, wire coils, and a cable that allows the stator to be connected to the voltage regulator. Magnets spin past the coils, which creates an electric current in the wires, which is then passed along to the voltage regulator, ...
What happens if your ATV stator goes bad?
If your stator is bad, the battery of your ATV will not charge while the ATV is running. This can be caused by several other problems, however, so the only way to be sure that your stator has gone bad is to perform a series of tests using a multimeter. In this article, you’ll find everything you need to know about your ATV’s stator, ...
Why do ATVs use three phase stators?
Three Phase Stators: Most ATVs use a three-phase stator because they are capable of producing more electricity. It uses three wires to create the coils that circle the iron core. The cable coming off the stator will clearly have three wires (usually yellow, but not always) if you have a three-phase stator.
What are the different types of stators?
There are three different types of stators: Single Phase Stators: Not as powerful. Uses a single wire to create the coils that circle the iron core. You will see two wires in the cable coming off the stator. Three Phase Stators: Most ATVs use a three-phase stator because they are capable of producing more electricity.
Can you clean a stator if it is bad?
You may need to clean the connectors. This is a free and easy fix so try it out if your battery is still good. Voltage regulator rectifier unit: If your voltage regulator is bad, you’ll have the same problems as if your stator is bad. This can make it difficult to determine, which is the problem.
Step 1: Original Stator
This is the original faulty stator. It has all of its 3 windings shorted to the metal body.
Step 2: Uncoiling the Thing
This is a quite tedious job, as the epoxy is quite hard to remove. You might need the help of a screwdriver to lift up the wire inside and between the poles. Be careful while handling the copper wire as you unwind it. Some of its insulating paint bits, still attached, are sharp and might cut your skin.
Step 3: Preparing the Support
Before recoiling the stator, make sure to prepare its surface, smoothing out with a file (or a minidrill) all the sharp edges. In my case this step was absolutely required as I mistakenly removed the epoxy residuals (as you can see in the first picture below) with a paint removal gel.
Step 4: Coiling Up!
Get some awg (diameter) enameled copper wire (transformer wire) as the original. In my case that was 0.95 mm diameter. I got mine from an electric motors rewinding shop. While you ask for the wire get also some insulating paint.
Step 5: Completing the Job
Once all the poles have been completed, the most is done. The whole stator need to be submersed into the insulating paint and put in oven to cure at 300F for 30 minutes. I did this twice to make sure a tick layer will form. After the paint has cooled its just a matter of soldering the connector wires back.
