How to fix common regulator/Stator failures

Discussion in '5th Generation 1998-2001' started by Rubo, Jul 7, 2012.

  1. OZ VFR

    OZ VFR Member

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    No continuity to ground is good.
    Also as Mello states, voltage from stator is AC not DC.
     
  2. Hans Olsson

    Hans Olsson New Member

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    Last edited: Aug 13, 2019
  3. skimad4x4

    skimad4x4 "Official" VFRWorld Greeter

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    If the max AC output from any leg of your stator is under 2 volts then your stator needs replacing. (I should be around 14 volts at idle and 60+ volts at 5,000rpm).

    To confirm that diagnosis just unbolt the stator cover and have a look inside at the stator.

    If you are greeted by a smell of burnt electrical windings and the windings have crispy fried sections then you know its time to buy a replacement OEM stator and stator cover gasket. If you are lucky you may find a specialist able to rewind the stator for less than a new stator from Honda but they would need the complete old stator with wires and connectors - so don't bin stuff if you are going that route.


    Take your time when you remove the old stator and make careful notes (photos) of what your removed from where - as it may be a few days before a replacement stator will be available from Honda parts.

    Rather than simply unbolt the old stator and cut off the old stator wiring - try to release the pins from the stator connector. Then attach with tape a length of spare wire to the end of the yellow wires. Then carefully pull through the yellow wires until they reach the other side of the bike to unbolt the old stator. Leave the spare wire in place - you will need it later to fit the new stator wires.

    Once you have your new stator, carefully disconnect the connector as you will find it is too big to pull through the gap below the engine. (Use a thin jewellers screwdriver to release the metal retaining lug on each individual wire from the connector.)

    Once the connector is off tape the three yellow wires onto the spare wire and then use it to pull the yellow wires back through to the other side of the bike.

    Then either reinstate the pins into the connector and attach it to the RR (it does not matter which order). Or eliminate the RR-Stator completely and just solder direct to the yellow wires from the RR.
     
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  4. Hans Olsson

    Hans Olsson New Member

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    I will take a look at it.
    Thank you!
     
  5. Hans Olsson

    Hans Olsson New Member

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    My stator looks like this! IMG_20190823_185446.jpg
     
  6. skimad4x4

    skimad4x4 "Official" VFRWorld Greeter

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    Yes that is dead.
     
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  7. mello dude

    mello dude Member

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    Agree - its toast...
     
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  8. Hans Olsson

    Hans Olsson New Member

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    With new stator and new regulator/rectifier it charges between 13.8 and 14.1 volts at the battery!
     
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