09 Charging Issue

[doolay1988]

Another charging problem on the 2009 1125CR y'all. I was on my way to MCAS Cherry Point one day and I noticed my voltage dropping mad fast. It dropped down to about 8 or 9 volts before she started spitting and sputtering. Luckily I only stopped short of 1/2 mile short of my storage unit. I charged the battery back up and reinstalled it. She started right up and seemed to be charging fine, but... as soon I rev'd above 2k the engine light came, followed by the battery light. My screen would show that voltage charging system error. I knew this model had issues and one day it was going to happen to me, but was ignorant and kept riding her. I'm fairly sure it's either my voltage regulator or stator. I was told I can check the stator by bypassing/disconnecting the regulator and reading the voltage directly. I attempted this yesterday but no luck; guess I didn't exactly know what or how to do so. Anyone have any input on this matter, much appreciated. It's a shame such an amazing bike just sits there... got to fix it!

 

[03Firebolt9R]

Try checking the relay, i have fried 3 relays in 2 years. You will know right away if it is toast. It is located under the seat and is a ten dollar part. If you have ridden awhile with it fried your vr or stator may be gone too. Good luck.

 

[vance580]

Sounds like the stator. Thats exactly what mine did when it went. To test the stator you pull the plug and put a volt meter set to A/C and see what you get from each pin. Each pin is a different phase so you put the red lead from the volt meter in there then ground the black. I believe in the 30 V A/C range is what you should get if one of them is below that then a phase is blown. It sounds like all your phases are blown cause all mine were and I had the same thing happen that you did. Once you pull the stator it will probably be burnt up. Here is mine all burnt up.

Here it was after I got back from Ricks before I reinstalled it all nice and rebuilt.

 

[vance580]

And actually I'm in the Raleigh area so if you don't know how to fix anything and don't want to take it to a dealer I can give you a hand since I saw you are at Cherry Point.

 

[crawfo]

I'm not trying to be a dick, but this is the first thing that popped into my head. Sorry man. EBR has the updated stator rotor for about 400 bucks. It is said to eliminate the burnt up stator issue for good.

 

[vance580]

They only have the rotor so he still needs to have the stator rewound.

 

[crawfo]

Correct, i was just letting him know that there was a long term option from EBR to help deal with the issue. I wasn't trying to make him think that the stator was included.....

 

[Huskerwannabe]

You get a core charge back on your old rotor so the total cost is about 150.

 

[doolay1988]

Thanks for the replies y'all.

Sounds like the stator.  Thats exactly what mine did when it went.  To test the stator you pull the plug and put a volt meter set to A/C and see what you get from each pin.  Each pin is a different phase so you put the red lead from the volt meter in there then ground the black.  I believe in the 30 V A/C range is what you should get if one of them is below that then a phase is blown.  It sounds like all your phases are blown cause all mine were and I had the same thing happen that you did.  Once you pull the stator it will probably be burnt up.  Here is mine all burnt up.

That's what I figured I needed to do, and as soon as this rain lets up I'll get on it.

I'm not trying to be a dick, but this is the first thing that popped into my head.

It's all good, had it coming to me.

 

[doolay1988]

Update*

Disconnected the wiring harness and my voltage reader read nearly nothing with the bike running at 2k [sad] fml

So I guess my next task is ripping the stator cover and all its guts... should be a party. I'll post pics on my progress.

 

[vance580]

It's not that hard when you take off the stator cover after you drain the oil. The only thing in the stator cover is the stator. When you remove the wires from the plug a good idea is to hook a wire or something to them so when you pull the wires through you will have that wire available to pull them back through when you go to reinstall. That's the hardest part of the reinstall is getting the wires back up to the plug. Don't forget to pick up a new gasket too cause mine broke as soon as I freed up the cover.

 

[poinographer]

[up]

In addition to all that, I recommend you attach *two* messenger wires, because when I was pulling my stator cable back through the harness my messenger slipped off and it was NOT fun to resolve that problem. I almost had to rotate the motor in the frame until I devised an alternative plan.

However, if you lead two messengers and the first one slips off then at least you'd have a backup... which I would then use to pull two more messengers through before trying again!

 

[doolay1988]

Update*
Pulled the cover off, and recovered the stator from it, and will be sending it off next week to have rewrapped at Rick's... but I've run into another problem with pulling the rotor. I ordered the crankshaft locking tool from EBR, but I can't seem to find the rotor puller itself :-/ ? Was wondering if anyone/place had one i could buy?

 

[doolay1988]

Tied some parachute cords to the connections, and thank god I tied two off. Like u mentioned poino, one slipped off while pulling her through.

 

[doolay1988]

Closer shot of the stator, and of the area I believe overheated. There's hair line cracks all over, and this particular area is completely black.

 

[poinographer]

Doolay, I used a plain old gear puller and it worked well for removing the rotor. No need for the special tool.

 

[doolay1988]

This helped out a bit

http://www.youtube.com/watch?v=5v2LtHlvcqI

http://www.youtube.com/watch?v=kDx3zgOLShY

 

[crawfo]

So do you have it back together yet? I'm just curious as to whether you replaced the stator with the updated version from EBR or not.

 

[doolay1988]

Yes I am using the updated stator, but it's all still getting fabricated and/or waiting for parts to arrive. A couple of videos showed drilled holes in your own rotor and whatnot, but that seemed too risky. They say it helped air cool the stator... but that's what the oil is for, so I dunno about all that... I just decided to go with the EBR version.

 

[doolay1988]

Question for y'all*

What size socket fits the rotor nut? 30, 31, 32MM?