Hi all, I have an apollo blazer 125cc atv that burnt out the stator. I bought a new one and that overheated and I pulled out the stator and resoldered a melted connection. I bought one more stator and noticed this one also gets very hot.
I bought one more ( 3rd one) never installed it in the quad and tested it with the others. all three have a blue/white, red/ black , yellow, white , and green wire. all three have continuity from the green to the yellow and to the white and also the metal center frame. when they get installed it allows the white and yellow wire to have continuity to the negative going to the battery. I am pretty sure by watching a few videos on the stator this isn't correct. any input on what is happening? the first 2 were cheap $15 stators from 2 different sources, the second was a bit more expensive. the quad does run with all of them in there, only problem is the stator just gets very hot and burns out. thanks in advance.

 

it allows the white and yellow wire to have continuity to the negative going to the battery.

They don't actually have full continuity, the circuits go through the coils, it is just the stator wires are thick enough not to have much resistance. On some the white goes to one side of the generator, yellow to the other, but on some each set of coils is earthed, so sends a separate AC wave via earth, to CDI in the case of black/red, and rectifier in the cases of the white and the yellow wires. I would suspect your rectifier if it is regularly burning out stators. Also check the wiring to ensure the coils are not shorted directly to earth.

 

Sounds like you have a melted wire in your harness, and it's grounding out, and melting your replacement stators.

Look carefully at your wiring harness and search for melted insulation. Hopefully, you can find it, and you won't have any more issues.

Hope you find the issue.

 

Hi, still burning up stators.
here is what i have tried to do to keep them from burning up
1. installed a custom harness that deleted some of the not needed wires (remote kill, wrist strap kill) new harness did not help
2. installed new cdi, rectifier, coil
3. battery is new just because old was dead from cold
4. started solonoid was changed cause it died
5. i have run it and tried unplugging all non essential parts to see if any shorts where in those parts (lights, horn, starter switch harness.
6. i have brought it to 2 mechanics the first said all my chinese stators that i was buying are junk. I have put in way too many at this point for them to all be this bad.
the second mechanic turned out to be most likely the guy who puts together the chinese quads at the dealer and was not a real mechanic. he said he fixed it. couldn't tell me what was wrong just said it was fixed and the next day i burned up another. called the mechanic back and all he wants to do is throw new parts at it. which i already did.
are there any other things I can try and check?

 

As far as I can see, the only way a coil can burn out is if it is shorted out. So, which coils are burning out? Blue white is from trigger coil, red/black is exciter coil for powering the CDI, white is one phase to rectifier, yellow another phase to rectifier. My guess is either yellow or white is shorting, as others would stop the ignition working if shorted. So only the yellow or white wires can be the problem. One of these wires is sometimes led to the choke, on automatic chokes, and light switch for those with AC lighting. Could you have the wrong rectifier/regulator fitted? I assume you changed like for like, so would have fitted another wrong one if the first was wrong. Rare now, but single phase rectifiers will have two input wires, as do three phase rectifiers that use earth as the third phase, but will be different internally.

 

this is an old thread but I did figure it out!!!! I was buying stators from different sources on the web. all were the incorrect stator. Apollo finally had stators in stock and that solved the problem. they all looked the same. an apollo dealer even sold me an incorrect stator. I finally was able to buy one direct from apollo and it has lasted 6 months now. the key difference was not continuity from the green to the white or yellow.

 

Right, so the coils are not earthed, making it a single phase alternator. The "wrong ones" must have been the more common three phase alternators, which use earth as the third phase.