I have an 07 with 8600 miles, bought new. Today I learned that despite a new battery, my stator is failing, i.e. it is charging somewhat but not fully. The fate of the regulator is as yet unknown. I would appreciate any input as to cause(s) of this situation. Apparently there is a ground fault in the unit and the prediction is that it will eventually cease charging althogether. I have ordered the parts, with a request that the dealer approach Kawasaki about a "goodwill" warranty, say split it with me, etc.

I searched this forum and found no other posts relative to stator failure. Any input would be appreciated.

Cheers,

Curtis

All I can say is to do all the inspections your self on the charging system per the manual. I looked at it and it doens't look that hard to figure out where the problem is using a meter. My problem is I dont trust any one, they could be selling you alot of expensive parts and all you have is a loose conection or another bad battery.

* Last updated by: buck20 on 9/10/2010 @ 2:49 PM *

Thanks Buck20.

Perhaps my situation sould be set forth in depth. First the bike perrformed flawlessly for the first three (3) years. The battery was maintained by regular use of a battery tender but finally died a natural death on March 6, 2010. My dealer did not have an OEM battery in stock so the appropriate Yusa battery (YTX14-B, 220 CCA) was used. This unit never did seem to return to full charge as readily as the OEM unit, which I put down to the "lesser" battery used. The problem progressed until (on June 12, 2010) I had my dealer look at the situation and a loose battery ground strap was discovered, after which all was rosy on the battery front.........for a while.

About three (3) weeks ago the battery started to show signs of weakness in starting although the slow recharging cycle did not reappear. I dismissed it as my failure to promptly hook the battery tender to the battery after my weekend ride due to laziness on my part. After leaving the battery tender off for a week through the labor day weekend, I went to start the bike to finally put it away and it barely started, exhibiting all the traits associated with a weak battery. I concluded the ground strap was again loose, although recharging was always prompt and quick on the battery tender. However, while warming the engine it abruptly died and when I restarted the clock and trip sets were reset, as if the battery had been disconected. A first occurence and upon the happening of which I resolved to take the bike in, which I did Friday Sept 10th whereat I was informed of the failing stator.

I have ridden HD for about fifty (50) years, inclucding about six years working in a HD dealerhsip (three (3) years of which were as a general manager of two (2) Harley dealerships, and although I remember some old gradual failure with generator windings, I cannot remember any gradual failures of the windings on a stator although I remember some magnets adrift on the rotors and loose take off wiring on the stators! However in all fairness my memory is not what it used to be.

Frankly, I was suspicious, especially after not finding the report of one (1) stator failure (gradual or abrupt) on this board. Besides things electric baffle me and your (Buck20's) suggestion that I check it out myself is frankly beyond me.

Sorry for the length,

Cheers,

Curtis

Thanks for the reply Blue07. As I recall the voltage was around 13.8 on the ride home from the "bad news" visit last Friday. I will check the readout in the various postures as suggested by you. I too wonder at the accuracy of the Stator failure diagnosis, mainly because of that "acute" interruption of power which occured on Labor day as outlined in my second post.

Anyway a replacement stator is ordered and I discussed with my dealer what will be the situation if the new stator does not cure the problem and he assured me in that event the cost of the stator was on them. He knows I'm a lawyer and have helped him for free in the past, so he probably wants to be kind to me. For my part I jsut don't want his new tech going to school on my nickel!

He further opined that the problem was that the loose ground strap (his error) caused an overload on the stator in that it had to produce more juice to make up for the lack of battery. This maybe, but makes no sense to me. How could this account for a broken winding (presumed stator fault by tests performed by his tech). Perhaps the regulator was overloaded having to constantly shunt alternator output between engine and battery, and it's condition is as yet undetermined.

Anyway, I will continue with updates as they occur as well as the eventual outcome. Also the service manager and I have agreed that we both would feel better if his number one tech (a man whom I respect and trust) would have a look when he returns from vacation next week.

I do not know if the terminal covers are in place, but I will find out and report.

Again, thanks for the input,

Curtis

Well the problem was a bad stator, which in turn fried the regulator/rectifier and the battery. There was visible evidence of heating on five (5) of the windings, interestingly those immediately adjacent to and on either side of the pickup wiring.

Anyway all new parts installed. There is some question of whether the Yausa replacement battery is sufficent. The original replacement (no OEM in stock) was YTX14-BS. It now has YTX14-H, the box was labeled 14Ah whereas the chart shows 12Ah.

Does anynone know the specifications of the OEM KHI battery? If so please provide them because I'm of half a mind to get the OEM battery, although it is quite expensive >$200.

Thanks,

Curtis

Thanks Blue07.

I was considering the OEM cause if something goes awray, I don't want somewone blaming my after market battery! I want to be able to say: Hey I'm running your Sh..!

Cheers,

Curtis