Electrical Charging question - Kawasaki Versys Forum
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post #1 of 29 (permalink) Old 10-06-2018, 01:54 PM Thread Starter
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Question Electrical Charging question

2009 Versys 650, 70000km.

Bike died on the road, the battery was not getting any charge. Bought a spare charged battery to get me home luckily until that drained.

Today I pulled the altenator lead. Checked the resistance which seemed good and then did the voltage test. I was getting nothing out. At idle or 4k rpm the meter didn't register any change at all.

My neighbour has the exact same bike. The resistance was the exact same as mine but the volts were in spec. When he started the bike, the volts were about 25 and at 4k rpm, they were about 42. 14v at the battery while the bike is running.

My bike starts and runs normally, just no juice coming from the stator.

I get a little confused on the terminology. The stater is the little motor that spins the engine to start the bike. Is the magenetic coil that generates the power called the altenator or stator?

Any advice where to go from here would be appreciated.

2009 650 Versys
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post #2 of 29 (permalink) Old 10-06-2018, 03:16 PM
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70,000 kms on original stator? Stator is part of your charging system. It's fried, mostly because of stock shunt-type regulator/rectifier. Some of us have upgraded to a series-type R/R.

https://en.wikipedia.org/wiki/Stator

It can be rewound or replaced.

https://www.kawasakiversys.com/forum...r-testing.html

Last edited by invader; 10-06-2018 at 03:20 PM.
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post #3 of 29 (permalink) Old 10-06-2018, 04:06 PM Thread Starter
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End of the season here so I have lots to read up on. Is replacing the stator a DIY kind of thing or does it require special shop tools?

Saw your avatar, funny I was born in Kapuskasing.

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2009 650 Versys
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post #4 of 29 (permalink) Old 10-06-2018, 04:33 PM Thread Starter
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If I got something like this would I need to change any other parts of the system too?

https://www.rmstator.com/en_ca/produ...6-2014-rm01041

2009 650 Versys
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post #5 of 29 (permalink) Old 10-06-2018, 07:27 PM
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The stator is all you need to make it work again, assuming your R/R is still good... You would however make your new stator run much cooler and last longer if you upgrade to a series type R/R.

Last edited by invader; 10-07-2018 at 09:38 AM.
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post #6 of 29 (permalink) Old 10-06-2018, 08:49 PM
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How To Forum

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Originally Posted by Crash View Post
2009 Versys 650, 70000km.

Bike died on the road, the battery was not getting any charge. Bought a spare charged battery to get me home luckily until that drained.

Today I pulled the altenator lead. Checked the resistance which seemed good and then did the voltage test. I was getting nothing out. At idle or 4k rpm the meter didn't register any change at all.

My neighbour has the exact same bike. The resistance was the exact same as mine but the volts were in spec. When he started the bike, the volts were about 25 and at 4k rpm, they were about 42. 14v at the battery while the bike is running.

My bike starts and runs normally, just no juice coming from the stator.

I get a little confused on the terminology. The stater is the little motor that spins the engine to start the bike. Is the magenetic coil that generates the power called the altenator or stator?

Any advice where to go from here would be appreciated.
I have like a complete book on this in the How to Forum, so much so that it is overwhelming to me , So I added some instructions and copied a few posts so it is in multiple threads.https://www.kawasakiversys.com/forum...gs-2015-a.html

The key to testing is using the idle screw adjustment, the video by skypilot shows him blip-ping the throttle , this serves no purpose, trust me , I have spent a lifetime involved with magnetic fields, AC & DC , what you want is a fixed approximately 2000 RPM after warm up, the fixed RPM is key to accuracy ( work =speed X energy , something like that), the value of volts AC should be within 1 VAC , from a phase to B, from B to C and C to A. You will see this in the video. Basically if 1 phase is off by 5 volts or more , the stator is toast, I included discussion about RM stator.
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post #7 of 29 (permalink) Old 10-07-2018, 10:47 AM Thread Starter
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Ok so a lot of reading for the winter The removal and install seems very straight forward, so now I just need to pick the replacement.

Hopefully I find out this one is good, since they are in Canada and the price does not seem too bad.

https://www.rmstator.com/en_ca/produ...6-2014-rm01041

2009 650 Versys
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post #8 of 29 (permalink) Old 10-07-2018, 10:56 AM
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FYI China Y connected Stator

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Originally Posted by Crash View Post
Ok so a lot of reading for the winter The removal and install seems very straight forward, so now I just need to pick the replacement.

Hopefully I find out this one is good, since they are in Canada and the price does not seem too bad.

https://www.rmstator.com/en_ca/produ...6-2014-rm01041
Man the price went sky high. Before I would buy that I would look at a used KLR or 650 Ninja. If you buy that, with shipping etc. you are halfway to OEM, and it isn't close to OEM

I will include a link in the Parts suppliers How To Forum. If you want equal to original equipment , Delta Wound Go to Electrosport

https://www.kawasakiversys.com/forum...er-forums.html

Last edited by onewizard; 10-07-2018 at 11:07 AM.
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post #9 of 29 (permalink) Old 10-07-2018, 11:12 AM Thread Starter
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So this one claims to be better than OEM, is that a true statement?

[url]https://www.electrosport.com/products/esg638-stator-kawasaki-zx-6r-zx-6rr

2009 650 Versys

Last edited by onewizard; 10-07-2018 at 11:15 AM.
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post #10 of 29 (permalink) Old 10-07-2018, 11:33 AM
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New / Equal To

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So this one claims to be better than OEM, is that a true statement?

[url]https://www.electrosport.com/products/esg638-stator-kawasaki-zx-6r-zx-6rr
From a technical standpoint, I worked for 9 years in a electric motor shop & on service, the Electrosport is epoxy encapsulated, 60% of stator failure is from vibration and crossover connections failing, encapsulating it protects the magnet wire, However the heat transfer is reduced, so the winding runs hotter.
What makes a huge difference is switching to a series regulator. Very simple, which piece of equipment lasts longer, one running at 100% load when possible, or one running at 65 to 70% load all the time ( which applies to a series regulator).

So if you never want the stator to ever fail again, buy either a china stator, the electrosport & install a series regulator ( highlight regulator as that is the deciding factor) I have numerous posts on this in this forum, the first link discusses electrosport and some feedback.



For some reason the links don't work, copy and paste in a new browser, something I have had happen before, this time it stuck.



https://www.kawasakiversys.com/forum...30-post19.html

https://www.kawasakiversys.com/forum...-question.html

https://www.kawasakiversys.com/forum...t=verses+delta

Last edited by onewizard; 10-07-2018 at 11:46 AM.
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post #11 of 29 (permalink) Old 10-07-2018, 11:56 AM
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Copied first link

Quote:
Originally Posted by onewizard View Post
From a technical standpoint, I worked for 9 years in a electric motor shop & on service, the Electrosport is epoxy encapsulated, 60% of stator failure is from vibration and crossover connections failing, encapsulating it protects the magnet wire, However the heat transfer is reduced, so the winding runs hotter.
What makes a huge difference is switching to a series regulator. Very simple, which piece of equipment lasts longer, one running at 100% load when possible, or one running at 65 to 70% load all the time ( which applies to a series regulator).

So if you never want the stator to ever fail again, buy either a china stator, the electrosport & install a series regulator ( highlight regulator as that is the deciding factor) I have numerous posts on this in this forum, the first link discusses electrosport and some feedback.



For some reason the links don't work, copy and paste in a new browser, something I have had happen before, this time it stuck.



https://www.kawasakiversys.com/forum...30-post19.html

https://www.kawasakiversys.com/forum...-question.html

https://www.kawasakiversys.com/forum...t=verses+delta
Something screwy for sure, happened before, just what us mods are wishing to have happen!! Pulled a work order, see what comes up
https://www.kawasakiversys.com/forum...ml#post1422330

Last edited by Testacc; 10-07-2018 at 11:59 AM.
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post #12 of 29 (permalink) Old 10-07-2018, 11:58 AM Thread Starter
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OK, I will see if they sell one of these series regulators too. Bike has 70K on it. I would like to keep it a few more years but not spend money that I don't need too.

I find it funny my 1971 CL 350 with original stator, regulator and rectifier still charges just fine

My Versys was supposed to be the reliable bike.

2009 650 Versys
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post #13 of 29 (permalink) Old 10-07-2018, 12:06 PM
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Winter Project Hang Tight

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OK, I will see if they sell one of these series regulators too. Bike has 70K on it. I would like to keep it a few more years but not spend money that I don't need too.

I find it funny my 1971 CL 350 with original stator, regulator and rectifier still charges just fine

My Versys was supposed to be the reliable bike.

I have a new option, one, wait until winter, one other member is installing the 4016868 Polaris , or I will find a used 4012941 Polaris one on Ebay, some time between now and December and PM you, the new Polaris ( 50 amp rated) is $128 Canadian whereas the 4012941 price got jacked and I suspect is discontinued at $228 .

I intend to do a install on my 2015 this winter, presently I have a CompuFire series regulator, which has worked on my 07 Versys and now my 2015, replacing it with the new Polaris as I have found the forward losses are less on the new Polaris ( less voltage drop = less heat produced / wasted energy in the form of heat), I may put my CompuFire up for sale in mid June 2019. Onewizard


https://www.kawasakiversys.com/forum...polaris+50+amp


https://www.kawasakiversys.com/forum...polaris+50+amp

Last edited by onewizard; 10-07-2018 at 12:13 PM. Reason: Signed back in as Mod from Test account.
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post #14 of 29 (permalink) Old 10-07-2018, 12:27 PM
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Used Polaris 4012941 Verified/Update PM / email notification

https://www.kawasakiversys.com/forum...ification.html

Since I did a quick look, anyone following this thread, here are 3 verified used 4012941;
I have verified these used ones, were possible you can try and offer about $35 to $40 USD This is a good seller from BC, have used him before

https://www.ebay.com/itm/Polaris-RZR...YAAOSw5SpbtST1

https://www.ebay.com/itm/EB478-2012-...UAAOSw~WNbsjtp

Another from Canada, never dealt with before, hard to see the photo, but definitely a 4012941

https://www.ebay.com/itm/09-13-Polar...YAAOSwHupbmp85

Last edited by onewizard; 10-07-2018 at 12:32 PM.
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post #15 of 29 (permalink) Old 10-07-2018, 04:03 PM
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Quote:
Originally Posted by onewizard View Post
I have like a complete book on this in the How to Forum, so much so that it is overwhelming to me , So I added some instructions and copied a few posts so it is in multiple threads.https://www.kawasakiversys.com/forum...gs-2015-a.html

The key to testing is using the idle screw adjustment, the video by skypilot shows him blip-ping the throttle , this serves no purpose, trust me , I have spent a lifetime involved with magnetic fields, AC & DC , what you want is a fixed approximately 2000 RPM after warm up, the fixed RPM is key to accuracy ( work =speed X energy , something like that), the value of volts AC should be within 1 VAC , from a phase to B, from B to C and C to A. You will see this in the video. Basically if 1 phase is off by 5 volts or more , the stator is toast, I included discussion about RM stator.
Must be a different skypilot. I've never posted any videos on this forum.
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post #16 of 29 (permalink) Old 10-08-2018, 06:59 AM
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Another Greeting from Charlotte NC

Just joined Forum. Was searching for some answers regards my repeated stator failures on 2011 650, purchased in 2013, now with 22k miles. Failed last summer, so replaced stator and regulator. Just failed again last week. I found my answer here in multiple threads--I need to put in new stator and new Series Polaris regulator which I just ordered off Ebay. Makes sense--I commute in stop and go traffic in 90deg F weather--stator gets pretty hot.
I especially thank onewizard for all his expertise. I wonder why Kawi continue to install such poor OEM design (probably $$), but really bad business to keep installing bad OEM parts with such frequent failures. Thanks again
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post #17 of 29 (permalink) Old 10-08-2018, 10:50 AM
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Sure Looks the Same To Me

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Must be a different skypilot. I've never posted any videos on this forum.
Just curious if someone hacked your account, as here it is :https://www.kawasakiversys.com/forum...93-post16.html
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post #18 of 29 (permalink) Old 10-08-2018, 01:13 PM
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This seems like a stupid question as I type, but I seriously can't find a straight forward answer. Several have talked of upgrading to a series type r/r, but I can't find any info on which one, specs, gotchas, etc. I haven't worked with electronics since like '96, so anything beyond the basics and I'm lost. Can someone point the way with a link?
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post #19 of 29 (permalink) Old 10-08-2018, 02:51 PM
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Originally Posted by sgtmango333 View Post
This seems like a stupid question as I type, but I seriously can't find a straight forward answer. Several have talked of upgrading to a series type r/r, but I can't find any info on which one, specs, gotchas, etc. I haven't worked with electronics since like '96, so anything beyond the basics and I'm lost. Can someone point the way with a link?
onewizard has posted MANY threads about changing to a series R/R. Try SEARCH using his name.

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post #20 of 29 (permalink) Old 10-08-2018, 10:19 PM
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Quote:
Originally Posted by sgtmango333 View Post
This seems like a stupid question as I type, but I seriously can't find a straight forward answer. Several have talked of upgrading to a series type r/r, but I can't find any info on which one, specs, gotchas, etc. I haven't worked with electronics since like '96, so anything beyond the basics and I'm lost. Can someone point the way with a link?
Not trying to be smart but this whole thread has tons of info, check post 10, notice the second paragraph, highlighted Series Regulator, The red text in that post are links, clicking the third one will get you to some of my technical stuff. Search stator, Polaris, CompuFire, all in the How To Forum, my guess is there is at least 24 continuous hours of reading minimum of my posts.

Presently I don't go into detail in anything but the How To Forum due to copyright protection. The basics are all over this forum, however I strive to keep photos and technical details in the How To Forum.
The latest version is discussed by me in post 13, Testacc is my troubleshooting login as a regular member. I have tested it and have photos of it, however it is more suited to a 2015 or newer 650 Versys. No one has installed it as of this writing, my plan as discussed earlier is to do it this winter.

Top of the screen is Tools, https://www.kawasakiversys.com/forum...searching.html
I have this in each forum under sticky. Keep it simple, lower right the default is All open forums, in the above search, scroll to the How To Forum , then below left click search.
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Last edited by onewizard; 10-09-2018 at 11:45 AM.
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