I just replaced the engine in my son's chinese ATV. The stator on the old engine has a yellow wire and a white wire, both tied together and connected to ground. The new engine stator has a yellow wire and a pink wire connected together, but not connected to ground. Is there a compatibilty issue with the voltage regulator or anything else?

 

I think you are going to have problems. Measure those wires again, but set your meter to the lowest scale you have (hopefully 20 ohms). What are the resistances between the yellow, and the white wire, to ground on your old stator?

What are the resistances between the yellow and pink wires on your new stator? Are you absolutely sure that both wires measure infinite resistance to ground (in other words open)?

 

The resistance between the pink and yellow is 1 ohm. Each wire to ground is an open circuit. I hooked them up just to see what would happen. No charging voltage until I turned on the headlight. I revved the engine and the headlight blew (up to 50V AC on the yellow wire to ground when revved). Do I need a different regulator, or do I need to get a 2 coil stator that will fit in the new engine? Could I ground the coil in the 6 coil stator the same as it is grounded in the 2 coil? I tried putting the old stator cover on the new engine, but the pickup is in a different place, so it would not start.

 

I think I can use the old stator cover with the old 2 coil stator and use some spacers and longer screws to move the pick up to where it will line up with the magneto in the new engine.

 

So is there topological (and fundamental) difference between the two stators? Is one a 6 pole star fish like configuration, and the other a two coil mounted side by side stator? Can you post some pic's of the two different stators?

This is sounding more and more complicated - but still solvable. So your lights are AC powered... Hmmm...

Is there anything else that is AC powered? Do you have an automatic choke (bystarter valve)? In other words do you have wires going to your carburetor?

If your stators are completely and fundamentally different, then the flywheel enters the picture too. The magnets embedded in the flywheel must exactly match the stator poles or the battery charge system will totally not work at all.

 

The new 6 coil stator would not work. I modified the old 2 wire stator by spacing the pickup to line up with the new engine, and everything works great, lights work, battery charges.

 

I'm glad you got it working...