| Author | Message | ||
     T9r |
So back in October 2009 on my way back from WI (One Last Ride) my 2004 XB12R with a little over 21k miles on the bike dies about 70 miles from home. I felt a bit lucky since it was a 14 hour motorcycle ride with minimal stopping. So after that ordeal it arrived home in the back of a pickup. So I replaced the aging battery and tried the bike out. The battery was zapped of most of it's power getting down to 10 volts while riding home from work on day in January. Finally Spring rolls around and I decide to look into fixing the bike.  Right now, I have diagnosed that the stator was bad by removing the right side pulley cover disconnecting the stator connector and testing the Ohms. The stator was grounded, so I removed the primary cover. Bad smell, I always thought the gear oil had a bad smell, so I didn't notice much different. Once I got the primary drive off this is what I found:  The wires on that third lead were brittle. Here is a side by side comparison:  The newer stator installed:  While I had it off I noticed that two of the magnets had come loose. So, upon consultation with others, I used JB Weld.   After it dried overnight I filed the JB Weld down:  I have thought about using JB Weld in between the other magnets, just in case they come loose in the future, welding them about 1/4" between magnets. I want to allow the oil to be sucked in and carried up to the top of the stator for cooling purposes. I now need to go to the dealer, which I called first, to pick up a new primary gasket. I hope to have it running right soon. I will also check the Voltage Regulator to verify functionality. | ||
| Lv_ss |
Doesn't the vr usually go when the stator goes bye bye? Make sure your dealer has one on hand. | ||
| T9r |
I've got a box of extra parts, and a VR which is where the stator came from. I'll see how long it lasts as they hit about 20k miles then die. I'll probably have to invest in a new one, stator w/in two years. At that time I'll look at the larger AMP Uly stators. | ||
| Froggy |
The Uly has the 100% exact same charging system as your bike. What oil do you use in your primary case? | ||
| Swampy |
Check the old wires very carefully where the metal protector plate holds them to the engine case, some times you find sharp edges on the retainer plate and that cuts the insulation and grounds the wires. Then for added protection put a big glob of silicone under the retainer plate before you reinstall everything. | ||
| T9r |
I had used the synthetic HD stuff. I'll add a dab to the wires under the plate. On the other side of the bike one of the wires from the VR or stator grounded out on a muffler bracket. That actually might have started the problem. | ||
| Nightripper |
I had a 1987 sportster do the exact same thing, the problem isn't in the windings its the bearings on the assembly that hold the magnets. Basically the unit flexs under the torque of the motor and distorts and rips off the magnets and tears up the windings. You need to replace the whole magnet section and the windings or it will happen again | ||
| Glitch |
T, I've done 2 stators. Both looked like your picture. Great post by the way. The first one at 20K was replaced under warranty, also fitted with a new VR. Second at around 40K without replacing the VR. At around 60K the VR gave out. I love how easy these bikes are to work on. | ||
| Reepicheep |
I agree! Great post! You up to 60k now Glitch? That's great! | ||
| Greg_e |
Did you check the balance on the rotor before installing it? Just wondering if the epoxy might have thrown it off which could cause a problem later down the road. | ||
| T9r |
I am going to remove all of the magnets and affix them with JB Weld, then they should be balanced. The epoxy is veryh lite weight compared to the whole assembly, like spit in a pool. I'll order the parts and store them for the next time it happens. When I mentioned my issue at the dealer they sounded suprised commenting that was not a common issue they saw. I didn't have the heart to tell him most Buell owners only use the dealer for parts and Buell clothes and most have cracked open the primary case at least once on their bike. | ||
| T9r |
Parts list: --Y1302.02A8 Voltage Regulator kit w/connectors --29971-02YA Stator Assy, 38amp, 3 phase --25378-02B Gasket, Primary Cover --25377-03A Gasket, Clutch Cover --34819-03A Gasket, Inspection Cover --11105 O-ring for primary drain plug | ||
| Glitch |
I didn't have the heart to tell him most Buell owners only use the dealer for parts and Buell clothes and most have cracked open the primary case at least once on their bike. That used to piss of the dealership I used to go to. "Cheap ass Buell riders" was said, I only smiled. All this time I though the H-D guys were supposed to be wrenchers. I guess the times have changed, or is it the riders have changed? | ||
| Whitexc |
RUB's(rich urban bikers) are the norm now. These guys don't wrench. If they do they aren't riding a new street glide, they are on an old FLH or something like that. Good post by the way. Thanks for sharing the info. | ||
| Firebolt32 |
like spit in a pool. Better spit than piss... Great post man! | ||
| T9r |
BTW a great resource thread on Charging System Diagnoisis: http://www.badweatherbikers.com/cgibin/discus/show .cgi?tpc=32777&post=1400571#POST1400571 | ||
| Glitch |
Jon always gives good advise, he's a great guy too. Hell of a rider as well. | ||
| T9r |
So ya saw all that hard work and the bike still did not produce enough AC off the stator, so I purchased a new stator and VR. BTW the stator passed the ground test, but not producing enough AC. Here is the new stator and the other one off a 2003 XB9R:  Other side:  I decided to swap out the magneto as well. When I put the magneto in the press to drive out the gear several of the magnets freed themselves from the magneto housing. So much for JB Weld under vibration. BTW I am replacing the eight bolts (HD part number 4751) on the front primary drive gear. They are 1/4" - 20 x 3/4", Grade 8. Fastenal had them for $5 per 100, while HD wanted $1/each. There are 21,389 miles on the bike now, we'll see how long the new Stator, and new VR last. I used HD Formula+ in the primary case. (Message edited by t9r on August 26, 2010) |
