hi all
currently travelling south America on an 89 tenere - stuck at moment as one part of the stator has melted - the coil there is now one melted together piece - resulting in no spark and so i wait for repair of the stator -

2 months earlier the wires inside the casing entering the stator had melted together and resulted in a similar problem of no spark. My queston is why am I suffering such heat/almost fire! problems here ? - The bike is old so I am not exceeding 4500 rpms and I am running it for 3 or 4 hour stints max with much stopping for fotos etc every 30 mins - 1 hour. Before I left for the trip I had to pull the oil - cooler off the bike as it was damaged and blocked and preventing oil circulation in the system. Any link? The day the stator gave up was after 2 hours heavy sand riding followed by 50kms asphalt.

Thanks everybody for the previous help

fward

One thing i found that is a cause of lots of elec problems is the two white wire connection plug coming from stator going to the rectifier box. Mine Was corroded and would heat up causing dim lights and dead battery on my 84. Butt connected the wires and no probs since! Just a thought! The plug will be in between the intake boots if routed correctly. Good luck

of the stator has melted?
There is a coil with thick wire, which is the alternator for the lights etc, and there's two smaller coils for the ignition (they charge the CDI).
If it is th first, I would think there is something wrong with your charging system, short circuit or something that makes the coil grill itself.
Then, never heard of a fried ignition coil, but they do break sometimes, that is true.

Do not think that removal of the oil cooler has caused this, as most XT's do not have this and run good and strong.

BTW, there are aftermarket stators on the market, you will only have to swap the pickups.

Auke

__________________
Auke
http://aukemarieke.blogspot.com

hi
just to follow up on this thread in case anyone else is having stator melt/ weak spark problems - Ive just had the stator repaired ( always the 2 coils for the ignition ) for the fifth time in 8 weeks here in S.America. To cut a long and very tiresome ordeal for me - for you - short, the last mechanic diagnosed the problem. The crankshaft was bent slightly and this coupled with the crankshaft bearings being outfitted with the finest chinese junk (thanks previous owner) resulted in my stator coil coming into contact with the rotor at obviously high speeds and temperatures. Fragments from the coil were then being churned around washing machine like and eventually ripping pieces out of the inner sleeve of the rotor aswell. Got the crankshaft done and the bearings replaced last week.

Unfortunately the stator went again yesterday - same story - weak spark, no start - when I checked, the damage to the inner sleeve was worse - I am putting this down to the mechanic not sanding down the damaged areas of the inner sleeve ( as requested) I am presuming that the protruding ripped up parts from before came into contact with the stator once more. I have worked the sleeve smooth and ordered the electrician to repair the 2 ignition coils but this time to construct them flush (same height) as the alternator coil.

Which is where my question comes in - has anyone out there got a stator handy or a good memory of how it looks - is the ignition part of it ( those two coils) the same height as the others for the alternator or slightly taller ? In other words does the stator exact a perfect outer circumference as you look at in the crankcase or do the ignition ones stand proud?

It would be a great help for me to know this - am wondering if it was a botched stator repair from before

thanks for the help

f