Stator Replacement/ Delta / Burnt Stator
It looks like the stator on my 2011 V650 is going. It's already the second one on this bike - first one was replaced under warranty by the previous owner at 18,000 miles. I'm now just north of 40,000 miles. A month ago, I replaced the original regulator with a Polaris 941 series regulator using the Triumph harness with all wires butt-spliced into the factory harness (stator connector still in place). I tested the stator and was seeing right at 24V on all three phases at 2000 rpm, so I believed that it was ok. After the regulator was installed, I measured 14.3V charging at 5000 rpm.
A couple of weeks after the regulator swap, my battery started dying regularly. Did some tests after a jump start and the charging voltage was lower, but figured it might be that the battery was so low. Was leaving town and didn't have a lot of time to trickle charge a battery overnight, plus the battery was the original one from 2011 - wouldn't be a bad thing to get a fresh one, so I did. Came back after 5 days away and it started up fine. After a few days of regular riding, it started dying again. I pulled accessories off and charged up the battery and still had the same issues and eventually the bike got to a point where it couldn't keep itself running, let alone charge the battery.
I'm now seeing 18.5/18.0/15.5 VAC between windings with the stator connector removed from the regulator, which is low, as is the DC charging voltage. I'm not sure my Fluke meter measures low resistance accurate enough but I'm seeing around 1 ohm between windings (higher than spec, if accurate) but also about 1.2 ohm between each winding and ground, which should be open circuit. Was in a hurry to run these tests, but I'm thinking one or more of the stator windings are shorting to the side cover. The bike did go down on its left side back in February.
A new stator from ElectroSport is on its way. Also ordering a new side cover gasket. Any other items I might need, besides a torque wrench with in-lb settings? I think I can just use standard gasket sealant (Permatex) for the mating sufaces, right? EDIT: I ordered ThreeBond TB1211 Silicone Gasket since I think the Kawasaki Bond stuff is just a faster-drying form of this as it's identified as TB1211F but sells for 3x the price of TB1211.
Also, what's the easiest way to lean the bike over to the right to remove the left side cover and keep everything (including excess oil) in place - maybe carefully propping it up against a wall?