Stator Installation: Things to look for

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  • IanDMacDonald
    XS-XJ Super Guru
    • Oct 2010
    • 3917
    • Grand Blanc & Fenton, MI

    #16
    I put some Trans gel on the outside ring of the stator, and it dropped right in place, after fighting with it for 30 minutes trying to get it in last night. I'll pull it back out today to see if it can go in any different.
    1979 XS1100F
    2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

    Comment

    • IanDMacDonald
      XS-XJ Super Guru
      • Oct 2010
      • 3917
      • Grand Blanc & Fenton, MI

      #17
      So, my mechanic buddy just told me that if the rotor was rubbing on the stator at any point, that it's junk. Is this true? Even after I shut it down, wiggled stuff around and started it back up, I still saw OL on the leads to ground, and charging voltage. Bike won't be started tI'll I figure out why it's hitting.
      1979 XS1100F
      2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

      Comment

      • crazy steve
        XS-XJ Guru MODERATOR
        • Jan 2009
        • 7932
        • Beautiful outer Yelm, WA

        #18
        Originally posted by IanDMacDonald
        So, my mechanic buddy just told me that if the rotor was rubbing on the stator at any point, that it's junk. Is this true?
        Not necessarily. Marks on the rotor and steel core should be smoothed off, but won't hurt the operation. If the rotor has been bent out of true, then it would need to be replaced. You may want to check for runout.
        Last edited by crazy steve; 04-08-2014, 11:48 AM.
        Fast, Cheap, Reliable... Pick any two

        '78E original owner - resto project
        '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
        '82 XJ rebuild project
        '80SG restified, red SOLD
        '79F parts...
        '81H more parts...

        Other current bikes:
        '93 XL1200 Anniversary Sportster 85RWHP
        '86 XL883/1200 Chopper
        '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
        Cage: '13 Mustang GT/CS with a few 'custom' touches
        Yep, can't leave nuthin' alone...

        Comment

        • IanDMacDonald
          XS-XJ Super Guru
          • Oct 2010
          • 3917
          • Grand Blanc & Fenton, MI

          #19
          So, got on this this morning. All electrical checks were good. Took a dremel to the rotor and brought the edges down, then followed with a sanding of the rotor. Cleaned the stator, verified it was clean, then put it back on. However, I believe I found my issue. The right side of the block has a broken piece that holds the locator dowel. I never worried about it, as there is no oil there. But, I talked to my motorcycle mechanic, and he said that the dowel holds the cover true. So, I just removed the broken piece, and have the cover mounted with four screws and one locator dowel on the left. Verified it was charging, saw nodrag marks on the rotor, and been riding it all day with my Fluke wired to the battery. In the process of looking for a LCD voltmeter gauge.
          1979 XS1100F
          2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

          Comment

          • crazy steve
            XS-XJ Guru MODERATOR
            • Jan 2009
            • 7932
            • Beautiful outer Yelm, WA

            #20
            If you're missing one of the locating dowels and can't replace it because of case damage, I'd use an adhesive sealer to attach the cover so as to hopefully prevent the cover from moving in use. That will make it hard to get off later, but may be cheap insurance...
            Fast, Cheap, Reliable... Pick any two

            '78E original owner - resto project
            '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
            '82 XJ rebuild project
            '80SG restified, red SOLD
            '79F parts...
            '81H more parts...

            Other current bikes:
            '93 XL1200 Anniversary Sportster 85RWHP
            '86 XL883/1200 Chopper
            '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
            Cage: '13 Mustang GT/CS with a few 'custom' touches
            Yep, can't leave nuthin' alone...

            Comment

            • IanDMacDonald
              XS-XJ Super Guru
              • Oct 2010
              • 3917
              • Grand Blanc & Fenton, MI

              #21
              Hmm. I'm almost scared to remove the cover again, lol.
              1979 XS1100F
              2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

              Comment

              • IanDMacDonald
                XS-XJ Super Guru
                • Oct 2010
                • 3917
                • Grand Blanc & Fenton, MI

                #22
                That's it, all buttoned-up and ready to ride hopefully. Ran it all day with my Fluke on it, and it kept charge. Went to Wal-Mart and bought an LCD voltmeter for $5 on clearance. Switched power works well. Just gotta figure out how to fix the hole in my case .

                Last edited by IanDMacDonald; 04-08-2014, 05:31 PM.
                1979 XS1100F
                2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                Comment

                • Winterhawk
                  XSive Maximus
                  • Jun 2004
                  • 684
                  • Missouri

                  #23
                  I too am having a charging problem. The Stator and Field Coils check out ohm wise, no short to ground on the white wires. I did have to make a connector for it off of a xj650 harness. The yellow went to the yellow. Does it mater which white wire goes to the other white wires in the harness plug?

                  Also I have 2 voltage regulators. Both have only 2 wires on the green and brown connector instead of 3 wires. Does this make a difference? I think both failed the test on the exact same diode according to the factory manual.

                  Didn't want to start a new thread as mine has a similar problem also.

                  Thanks for the help.
                  "We are often so caught up in our destination that we forget to appreciate the journey." "

                  Comment

                  • IanDMacDonald
                    XS-XJ Super Guru
                    • Oct 2010
                    • 3917
                    • Grand Blanc & Fenton, MI

                    #24
                    I'm not 100% for sure that it matters or not, but I would attempt to put them back in the order that they were in, as each wire is a ddtator phase winding. As to your regulators only having two white wires? Doesn't sound like an XS1100 R/R then, as it should have the same three white wires, in-addition to have a brown and green (maybe black too) coming off it.
                    1979 XS1100F
                    2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                    Comment

                    • IanDMacDonald
                      XS-XJ Super Guru
                      • Oct 2010
                      • 3917
                      • Grand Blanc & Fenton, MI

                      #25
                      And, btw, I'm not sure the Clymer manual is 100% right on the diode tests. One of them says to goto B, and there is no B labeled. I don't think my R/R passed that test, but it's still working. Geezer R/R is in my future.
                      1979 XS1100F
                      2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                      Comment

                      • bikerphil
                        Master of XSology
                        • Jan 2008
                        • 8633
                        • South Flori-DUH

                        #26
                        I am pretty sure with the white wires there is no specific order, I just rebuilt the charging system section of my harness eliminating the plugs (not paying close attention to the orientation) and I'm sure I mixed the white wires up, works just fine. The yellow wire (78-79) must go to the yel for the headlight relay trigger.

                        Edit: The regulator 3rd wire (black ground) was eliminated at some point, probably not necessary as the unit grounds thru it's chassis.
                        Last edited by bikerphil; 04-09-2014, 08:16 AM.
                        2H7 (79) owned since '89
                        3H3 owned since '06

                        "If it ain't broke, modify it"

                        Comment

                        • crazy steve
                          XS-XJ Guru MODERATOR
                          • Jan 2009
                          • 7932
                          • Beautiful outer Yelm, WA

                          #27
                          Originally posted by bikerphil
                          I am pretty sure with the white wires there is no specific order...
                          As long as they're white-to-white, it makes no difference....
                          Fast, Cheap, Reliable... Pick any two

                          '78E original owner - resto project
                          '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
                          '82 XJ rebuild project
                          '80SG restified, red SOLD
                          '79F parts...
                          '81H more parts...

                          Other current bikes:
                          '93 XL1200 Anniversary Sportster 85RWHP
                          '86 XL883/1200 Chopper
                          '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
                          Cage: '13 Mustang GT/CS with a few 'custom' touches
                          Yep, can't leave nuthin' alone...

                          Comment

                          • bikerphil
                            Master of XSology
                            • Jan 2008
                            • 8633
                            • South Flori-DUH

                            #28
                            Yep Steve, that's what I meant, thanks for clearing that up. I might add that eliminating the connector behing the fuse panel and the one at the voltage regulator and using new 14g wire gave me some awesome charging voltage.
                            Last edited by bikerphil; 04-09-2014, 09:57 AM.
                            2H7 (79) owned since '89
                            3H3 owned since '06

                            "If it ain't broke, modify it"

                            Comment

                            • IanDMacDonald
                              XS-XJ Super Guru
                              • Oct 2010
                              • 3917
                              • Grand Blanc & Fenton, MI

                              #29
                              I'm curious how much more voltage? I think the highest I see on my bike is 14.5v.
                              1979 XS1100F
                              2H9 Mod, Truck-Lite LED Headlight, TECHNA-FIT S/S Brake Lines, Rear Air Shocks, TKAT Fork Brace, Dyna DC-I Coils, TC Fuse Block, Barnett HD Clutch Springs, Superbike Handlebars, V-Star 650 ACCT, NGK Irridium Plugs, OEM Exhaust. CNC-Cut 2nd Gear Dogs; Ported/Milled Head; Modded Airbox: 8x8 Wix Panel Filter; #137.5 Main Jet, Viper Yellow Paint, Michelin Pilot Activ F/R, Interstate AGM Battery, 14MM MC, Maier Fairing, Cree LED Fog Lights.

                              Comment

                              • bikerphil
                                Master of XSology
                                • Jan 2008
                                • 8633
                                • South Flori-DUH

                                #30
                                Yep, that's what I have, about 14.5V, my connectors had seen better days, they had to go.
                                2H7 (79) owned since '89
                                3H3 owned since '06

                                "If it ain't broke, modify it"

                                Comment

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