Unique Stator fault... Is it fixable??

[jakefromstatefarm]

Hi guys -

I'm currently working through the charging system on my 1979 xs400 in search of at least one gremlin. I can get the bike to start, but it won't run for more than a minute before it eats up its own juice and dies. I determined that the stator was shorting out thanks to some awesome threads on this site. Upon inspection, I noticed one of the many copper? coil-loop-things that surround the rotor was bent down, pinched against the inner metal wall of the stator, and ground down a bit by the rotor - enough that the copper strand was broke through. In the below/attached photograph, you'll see the two ends of the strand bent back up and crossed against each other.

Was the problem that they were making contact with the stator body? Or is it also a problem that the wire is broken? If so, is there a recommended way to reconnect the wire?

Thanks everybody!

 

[16VGTIDave]

Wire broken = 1/3 of charging gone.
Wire grounded = possible rectifier damage.

Take it to an alternator repair shop to have it rewound, or try splicing it yourself if you are good enough. There looks to be just enough wire to work with.

 

[BBS360]

An open wye ends up delivering only 57.7% of original power. Reduced voltage and current.

I personally wouldn't attempt a repair. Just asking for trouble down the road.
Get the whole thing rewound.
I don't have the link but there was a member who mailed their stator to a rewind shop that did a great job for a very reasonable price.

 

[drewpy]

I'd just get a new stator. the wires are vacuum bonded together in a special varnish.
cheaper to get a new one ( more reliable too)

 

[jakefromstatefarm]

@drewpy
Where do you recommend I get a new one? The custom rewind guy apparently throws in new wiring in and out of the stator which I also need.
Thanks.

 

[jakefromstatefarm]

Somebody said his total charge was $140 after shipping. I can't find any new replacement stators online at all, and if I were to find one, it looks like it'd be a little more expensive. Any ideas?

 

[BBS360]

I seem to recall reading that the work on the rewound stator was very good.
Probably the route I'd go. I don't think you'll find a "new" stator.

 

[drewpy]

i meant new to you not brand new

you could get the part number and google it, I got new brand new camshafts for the FZ doing that

 

[MrStubb]

I know in Minneapolis there are a number of electric motor repair shops. Also a number of alternator shops to choose from. Personally I used to deal with Broadway Robbinsdale Auto electric but I think they're out of business. I think if you check the yellow pages under Starter Alternator or Electric motor repair you'll find a number of reputable shops.