I've been having electrical problems with my 05 400 Sportsman, specifically intermittently overcharging to 18-19 volts and battery light flashing. I replaced the control module/voltage regulator and within a few minutes riding had the overcharging again (battery light flashing) for a brief period and now the system is not charging at all but the battery light is not flashing.

In checking the stator, all 3 yellow wires from the stator to the control module show continuity to ground which as I understand it means the stator is bad. Is this correct?

Also, will the machine run with a bad stator? It still starts and runs fine but doesn't show any increase in voltage at the battery on rev up.

Electrical stuff always gives me fits.... any help is appreciated!

 

maybe some one w/ a service manual can look up the info for ya to test it. if you wouldnt have said you replaced the recifier i would say that since it controlls the voltage.

 

Thanks for the reply.

I have a manual and went through the tests which seems to confirm the stator being bad but when I pulled it along with the harness there doesn't appear to be any damage to it or the wiring.

 

For future reference for anyone else who might run into this problem, the stator is bad, it should not be shorted to ground. The bike can also run fine with a bad stator until it drains the battery as the cdi is powered by the battery voltage.

New oem is $300-350, I'm getting one through RM Stator for approximately $125 plus shipping.

Jim

 

I took off my recoil starter cover knowing I had muddy water in there because it gets by the pull rope's handle and into the housing. I was horrified to find out that that cover is all that protects the expensive stator, pulse coil ,fly wheel and Bendix drive from water. I had to sand the fly wheel and pules coil contacts of rust to get a strong spark back.

I was use to my Yamaha where if water gets in the recoil housing its just a nuisance not a potential $$$$$$$$$$ problem.

Maybe your stator just took one to many baths.

 

<div class="FTQUOTE"><begin quote>Originally posted by: TLC

Maybe your stator just took one to many baths.</end quote></div>


Very possible....[img]i/expressions/face-icon-small-wink.gif[/img]

I agree, not the greatest design.

 

good info to have lotus thanks for the info and thats a good price on a stator.

 

Update-

Replaced stator with new unit from RM Stator and everything is working great now. Great people to deal with, I highly recommend them.