Question about 2002 Yamaha V Star 1100 Custom

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Wire connector between stator & voltage reg/rectifier burnt

My stator on 01 V-Star 650 Classic went out 6 months ago. I replaced it (& pick up coil while I was there) & started charging fine. I removed the tank this weekend to do tune up & found stator wire connector between stator & voltage reg/rectifier burnt. I repaired/replaced connector. Wires get very hot in less than 5 min. of running. Book says stator wires should read .5 ohms. They read .3. What is burning the wires/stator? Can you test the voltage regulator/rectifier? Book says if voltage is 14V @ 5000 rmp, voltage regulator/rectifer ok. I don't have tach but I only achieve around 13.5 when reved up. Any ideas?

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Your voltage/reg. can be tested in a couple different ways check ground res. check res. then revs. bias on diodes you have ac in dc out it sounds like you may have a diode gone bad allowing ac curent to flow causing the wires to get hot

Posted on Jul 31, 2009

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Lower beam went out, then when switched the switch to the upper beam it made a loud pop and blew the light. no fuses are blown and replaced the head light . now i have no light at all


Hi, Cheri if your headlight is not working, keeps burning out, blinking, or is dim the first thing you need to check is the headlight bulb for damaged filaments then check your light circuit fuse, that being said the usual suspects are:
1. Faulty ground or power supply wire to headlight bulb socket.
2. Worn, chaffed, or broken wires in the light circuit.
3. Corroded, broken, or loose pins/sockets in wire connectors.
4. Faulty hi/lo beam switch.
5. Faulty ignition switch.
6. Fuse is good but no continuity on both sides.
7. Faulty wiring between battery positive and headlight bulb socket.
8. Weak charging alternator/generator.
9. Faulty voltage regulator/rectifier, overcharging.
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Sep 11, 2013 | 2004 Yamaha V Star Classic

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Yamaha V Star Classic 650 headlight does not work at all... please help...


Hi, William if your headlight is not working, only one beam works, keeps burning out, blinking, or is dim the first thing you need to check is the headlight bulb for damaged filaments then check your light circuit fuse, then check your head light bulb socket ground wire for a clean tight connection, that being said the usual suspects are:
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2. Worn down solder contacts or loose fit of the bulb base in the socket due to vibration.
3. Worn, chaffed, or broken wires in the light circuit.
4. Corroded, broken, or loose pins/sockets in wire connectors.
5. Faulty hi/lo beam switch.
6. Faulty ignition switch.
7. Fuse is good but no continuity on both sides.
8. Faulty wiring between battery positive and headlight bulb socket.
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10. Faulty voltage regulator/rectifier ground or overcharging.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Apr 26, 2013 | Yamaha V Star Classic 650 Motorcycles

1 Answer

MTD yard Machine lawnmower,17hp Briggs And Stratton engine. Runs for about 15 or 20 minutes and stalls. It will not start again until I recharge the battery over night. Then only runs again for 15 or 20...


yes it could be

check your battery 1st , then check the stator a/c output

• 10 or 16 Amps DC regulated for charging
battery
• Two black leads (C) from stator
• Yellow connector (D) with two pin
terminals
• Two yellow leads (E) to regulator-rectifier
(F)
• One red lead (B) from regulator-rectifier
to red connector output lead (A)
• 10 and 16 Amp systems use the same
stator, color coding and regulator-rectifier
• Alternator output is determined by the
flywheel alternator magnet size


The stator and regulator-rectifier are the same
for the 10 and 16 Amp systems. The system
output is determined by the flywheel magnet
size.
Test Alternator Output
1. Temporarily disconnect stator wire
harness from the regulator-rectifier.
2. Insert RED test lead (A, Figure 28) into the
V ω receptacle in the meter.
3. Insert BLACK test lead (B) into COM
receptacle.
4. Rotate selector to AC Volts position.
5. Insert RED (A) and BLACK (B) test lead
probes into output terminals (D & E) in
YELLOW connector (C). (Test clip leads
may be attached to either terminal).
6. With the engine running at 3600 rpm, the
output should be no less than:
• 20 volts - 10 Amp System
• 30 volts - 16 Amp System
7. If No or Low output is found, check for
bare wires or other defects. If wiring
defects are not found, replace the stator.
voltage depending on alternator type and magnet size

then check the regulator / rectifier , make sure it is grounded properly

make sure battery earth lead is good

i suspect loss of bat voltage is letting the afterfire solenoid close off the main jet

let me know model and type codes off engine & i will try help further

cheers

Aug 29, 2010 | Briggs & Stratton Garden

1 Answer

Need to check out and possibly replace rectifier on 1982 Suzuki GS 1100L My battery is not charging.


It's much more likely that its the stator although they do do the odd regulator as well.
Start at the stator first as it is easier to test.
Disconect the stator wires-sometimes behind the front sprocket cover-sometimes further up the wiring loom.
Using a multimeter check for resistance between the yellow wires (3x) comming from the stator cover. Check that none of these wires has conunuity(connection) to earth.
If any/all do you have a burnt out stator- remove the stator cover & inspect- the windings will look burnt & smell bad also.

If the stator tests fine then the reg is most likely the problem.

Hope this helps-
Regards Andrew

Jul 18, 2010 | Suzuki GS 750 L Motorcycles

1 Answer

Charging problem


Hi
As the battery & regulator/rectifier have been replaced, the only other things to check are :-
Continuity from reg/rect red wire to battery & to earth, then check for continuity between each of the 3 yellow wires, all should be the same resistance - if not the stator coils in the alternator are faulty

Ride safe
Bike-Doc
Please mark this as very helpful (if it has been!!)

May 06, 2010 | 2006 Yamaha V Star Classic

2 Answers

My battery wont charge and I just bought it


Hi and welcome to FixYA,

Two possibilities:
  • rectifier / regulator combo (most likely);
  • corroded, burned, loose connection from the stator to the regulator (likely);
  • faulty stator (least likely).
The stator would be producing relatively high AC voltage while revving the bike. The stator output AC voltage are fed to the rectifier / regulator through 3 white wires. Check calls for testiing for the presence of the AC voltage on any pairing of the white wires before and after the connector before the voltage regulator. Check on the regulator calls for checking the battery voltage when revving the bike (14.5 VDC).

Good luck and thank you for asking FixYa.

Jan 04, 2010 | 2002 Yamaha YZF Thunder ace 1000 R

1 Answer

Two years ago my Voltage Regulator went bad and over-charged my new battery to the point that it swelled up. The Yamaha dealership replaced both the battery and Voltage Regulator. Two years, almost to the...


If you're going through regulators that often I would suggest going after the stator. Make sure it's not grounding out on the chassis. Find the 3 yellow or white wires that are connected to the regulator. using a meter in OHMS ( looks like the horseshoe ) with the bike off check wire one (red ) to wire 2 ( black ) then wire one ( red ) to 3 (black ), then 2 (red ) to 1 ( black ) and 2 ( red ) to 3 ( black ) , then pick one ( red ) and black to the chassis, motor, ground. somewhere metal on the bike. The first series of tests you should get some sort of numbers, ( which should be somewhat close in numbers ) When you go to ground, Chassis you should get no numbers, OFL, OL, or the horseshoe sign if you get numbers there, the stator is bad and your transmitting ac voltage to the chassis.

Aug 27, 2009 | 2000 Yamaha V Star 1100 Classic

1 Answer

2002 V Star 1100 voltage problems


oh yes..........
voltage regulator.... this unit also contains the rectifier which changes generator electricty from AC to DC for the battery. test the volt reg and it may be ok for the volts, but if the rectifier part is knackered, it will completely screw up every battery, they will not take AC !!!! every time I get a bike in for repair with volt reg. probs I always put in a new battery

Aug 07, 2009 | 2002 Yamaha V Star Classic

1 Answer

Faulty regulator rectifier- can't start the bike


I have a '07 C90T.
I have just replaced my stator. I replaced the reg/rectifier earlier this year. I replaced the battery one year ago in October.

I firmly believe what started the problem. Two guys that I told I didn't need help, but they pressured me to let them help. They hooked a battery backwards to my bike. A lot of people believe that's what shortened the life of the rectifier and stator.

But keep this in mind. The connections for the regulator/rectifier are not waterproof. I had done a lot of rainy riding and I first found a burnt connector on the discharge side of the reg/rect. My mechanic told me I needed to replace the reg/rect so I did but I soldered the wires and made them waterproof. I didn't do this on the stator side of the reg/rect and a few months later, when the bike quit charging again, I found that connector burnt, so I cut it out and soldered and waterproofed it.

Two days after we got back from a 700 mile round trip to Red River, NM, my bike quit charging again. This time though, I have a voltage meter on the bike, so I was aware of the problem before the bike could strand me someplace. Get one of those btw.
When I checked the old stator after I replaced it, I found the stator good but the pulse signal generator bad. It's required that you replace both btw. You have to, they are joined at the grommet.

Ok well, the battery cost $60 last year and I replaced it myself.
The reg/rect cost $140 through my mechanic and I replaced it myself.
Got the stator online for $173 shipped and they advertise a better stator that puts out 20% more power.
Not counting little things like solder, tape, heatshrink and such, I'm out a little less than $375 on my charging system.
I hope it's a done deal.
Again, some think the problems began when the battery was hooked up wrong, but I lean to believe the sub-standard Suzuki connections may have a hand in this.
Hope this helps. . . Joe

Jun 18, 2009 | 2007 Suzuki Boulevard

3 Answers

Charging system problem


sounds like the stator may be grounded

May 14, 2009 | 2000 Harley Davidson FLSTC Heritage...

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