Stator test with low voltage output
 

My battery has died due overcharging, so I've been doing test's to see what's wrong. I would say that my r/r is probably toast...it was a decent mosfet based one and only a year old, so there must be something else wrong with the system. Taking the r/r out of the equation I tested the ohms and all three wires were showing 0.5ohms. Next tested the continuity with ground on all 3 wires...no continuity, so that's fine. Tested the stator output and at 5000 revs it's showing 49 volts on each wire. The readings should be a minimum of 60v each. Does anyone know what would cause such a low output?

Re: Stator test with low voltage output
 

Are you doing it with the RR disconnected? I would have said 75V minimum but yeah 49 is low. Are you sure of the accuracy of your multimeter? Using it on AC mode not DC? Connecting it to a pair of wires from the stator, not to anything else? Sure you don't have any continuity to earth? If in doubt, double check all this stuff.

Re: Stator test with low voltage output
 

Yes, the r/r is disconnected. I used two different multimeters, so I know it works OK. Yes, it was on AC not dc. Definitely no continuity to earth. I've been reading a brilliant thread on here for testing everything, so I'll be checking everything again tomorrow.

Re: Stator test with low voltage output
 

Broken/weak magnet on rotor?

Re: Stator test with low voltage output
 

That's what I'm thinking. It's always something...I've spent so much time fixing the bike that the summer has passed me by.

Re: Stator test with low voltage output
 

I'd check the magnets for tightness and then I'd fit a new R/R (since your old one was overcharging) and see what your battery voltage is at idle and at 2k rpm.

Re: Stator test with low voltage output
 

I re-did the stator check, as I was doing it wrong...I was doing it to ground. At idle I have 30vac and 5000 revs its 100vac on all three pairs. Is this OK? I have a new r/r from a gixxer, is the voltage too high, or is it fine...I don't want to blow this one.

Re: Stator test with low voltage output
 

The manual just says more than 60V at 5000. My opinion is it should be fine.

Re: Stator test with low voltage output
 

It seems to work well, a nice 14.5v on the battery. It's made my day :) Then it started raining. lol

Re: Stator test with low voltage output
 

good news but still hasnt answered why the original RR failed. You didnt jump/bump start the bike with a flat battery at some stage did you? In fact how do you know the battery died of overcharging? Also was the RR cooled as best as possible?