950 stator rewind?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by dirtyboy, Dec 22, 2005.

  1. RedFlash

    RedFlash Go Cubs!

    Joined:
    Feb 10, 2005
    Oddometer:
    2,440
    Location:
    Home of the Chicago Cubs!
    cpmodem, will the stator phase-to-phase AC output be 50 volts at idle? For permanent magnet generators, I have seen them read only 10 to 20 volts. The voltage increases with engine speed, usually reaching a peak voltage where additional engine speed has no further effect (about 5000 rpm on my 525 stator upgrade). I have never measured the output on the 950, so maybe it has some wicked strong magnets flying around :eek1 !

    :1drink
    #21
  2. autorotate

    autorotate Adventurer

    Joined:
    Mar 31, 2005
    Oddometer:
    87
    Location:
    El Paso
    So I button her back up and go for a ride out to Santa Teresa airport (5T6), then to dinner, then back home. Use the Aux lights, GPS and grip heaters the whole time. Probably about a total of 45 minute ride.

    <st1:place w:st="on">Battery</st1:place> reads 12.7 Volts on my return......<!--[if gte vml 1]><v:shapetype id="_x0000_t75" coordsize="21600,21600" o:spt="75" o:preferrelative="t" path="m@4@5l@4@11@9@11@9@5xe" filled="f" stroked="f"> <v:stroke joinstyle="miter"/> <v:formulas> <v:f eqn="if lineDrawn pixelLineWidth 0"/> <v:f eqn="sum @0 1 0"/> <v:f eqn="sum 0 0 @1"/> <v:f eqn="prod @2 1 2"/> <v:f eqn="prod @3 21600 pixelWidth"/> <v:f eqn="prod @3 21600 pixelHeight"/> <v:f eqn="sum @0 0 1"/> <v:f eqn="prod @6 1 2"/> <v:f eqn="prod @7 21600 pixelWidth"/> <v:f eqn="sum @8 21600 0"/> <v:f eqn="prod @7 21600 pixelHeight"/> <v:f eqn="sum @10 21600 0"/> </v:formulas> <v:path o:extrusionok="f" gradientshapeok="t" o:connecttype="rect"/> <o:lock v:ext="edit" aspectratio="t"/> </v:shapetype><v:shape id="_x0000_i1025" type="#_x0000_t75" alt="" style='width:11.25pt; height:11.25pt'> <v:imagedata src="file:///C:\DOCUME~1\TIMOTH~1.VAU\LOCALS~1\Temp\msohtml1\01\clip_image001.gif" o:href="http://s3.amazonaws.com/advrider/bncry.gif"/> </v:shape><![endif]--><!--[if !vml]-->:cry<!--[endif]-->

    I was hoping I squared away a loose connection or corroded ground in my exploration through the bike....I guess not.

    I recheck the stator output checking from Pin to Pin vs Pin to ground and I get:

    Pin 1 to Pin 2
    Idle: 21.2 VAC
    3K: 37.2 VAC
    5K: 60.4 VAC

    Pin 1 to Pin 3
    Idle: 22.0 VAC
    3K: 36.4 VAC
    5K: 58.6 VAC

    Pin 2 to Pin 3
    Idle: 21.8 VAC
    3K: 36.1 VAC
    5K: 59.7 VAC

    I'm accounting for the variances in voltages between the three phases as due to a Saturday night BAC<!--[if gte vml 1]><v:shape id="_x0000_i1026" type="#_x0000_t75" alt="" style='width:42.75pt;height:21pt'> <v:imagedata src="file:///C:\DOCUME~1\TIMOTH~1.VAU\LOCALS~1\Temp\msohtml1\01\clip_image002.gif" o:href="http://s3.amazonaws.com/advrider/friday.gif"/> </v:shape><![endif]--><!--[if !vml]-->:freaky<!--[endif]--> and my ability to hold the throttle precisely.<!--[if gte vml 1]><v:shape id="_x0000_i1027" type="#_x0000_t75" alt="" style='width:11.25pt;height:11.25pt'> <v:imagedata src="file:///C:\DOCUME~1\TIMOTH~1.VAU\LOCALS~1\Temp\msohtml1\01\clip_image003.gif" o:href="http://s3.amazonaws.com/advrider/mwink.gif"/> </v:shape><![endif]--><!--[if !vml]-->:wink:<!--[endif]-->

    So good news, I think I've narrowed it down to a voltage regulator/rectifier...

    Bad news it's $123 from Holeshot...I guess it's not that bad, at least I found the culprit....I think.
    http://www.ktmamerica.com/ktmparts/default.php?s_PartNum=60011034000&s_ProductName=

    I been chewing on this...I had the first service done by a convenient dealer (due to the timing, I was doing the military no home shuffle between "homes" at the time). I've noticed that they weren't as particular about where the old engine oil seemed to go on it's way out the oil tank.....like all over the regulator and connector....I wonder if this thing got hot between the time it was bathed in old engine oil, collected 2K miles worth on KTM Dual Sport dust and fun, and then was cleaned by myself at the next oil change....things that make you go hmmm....

    Anywho...thanks for the help ADVrider.
    #22
  3. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,116
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    Nothing special about the 950 generator. You're absolutely right about them being rpms effected. I usually run 'em up to about 3k to check output. The important thing is that all phases are close to equal. The 50 vac figure is a generalization applicable to all of these 3 phase stators. I wouldn't be suprised if the LC8 gen puts out something different, but it will not be very far off. I'll check a known good one when I get back to the shop, so Gert and Autorotate have something to start from.
    -cp
    #23
  4. autorotate

    autorotate Adventurer

    Joined:
    Mar 31, 2005
    Oddometer:
    87
    Location:
    El Paso
    It's got to be the voltage regulator/rectifier now......right?:ear
    #24
  5. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,116
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    Sorry, I missed your last post while answering Redflash. From the looks of your last voltage reading, it looks like the stator is fine. Next culprit on my list would be the reg. That's a lot of $$$, but I guess that's what its gonna take to get back on the road. Good news is it sounds like your battery is in great shape :clap
    -cp
    #25
  6. 950TRANSALP

    950TRANSALP Been here awhile

    Joined:
    Apr 15, 2005
    Oddometer:
    795
    Location:
    Jackson , Wyoming
    :ear Did you say auxillary fuel tank switch !????? Please explaine ??? K.B.
    #26
  7. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,116
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    I installed a 5.5 gal fuel cell custom built for me by BLM Accessories:
    http://www.blm-accessories.com/FuelCells.cfm
    It is easily mounted/removed with 4 bolts. I use it for LD Rallys and long rides where gas stations are far and few between. It extends my range to over 400 miles. The switch energizes a solinoid fuel valve near the fuel pump that switches the pump between main tanks and fuel cell.
    -cp

    [​IMG]
    #27
  8. RedFlash

    RedFlash Go Cubs!

    Joined:
    Feb 10, 2005
    Oddometer:
    2,440
    Location:
    Home of the Chicago Cubs!
    Thanks! I'll save this thread for future reference :patch ...

    Right now I'm troubleshooting a bad rectifier/regulator I got with an Electrosport kit for the 525. Brand new out of the box and it's DOA to my door :bluduh ...


    At least the ignition coil is good :lol3 .
    #28
  9. 950TRANSALP

    950TRANSALP Been here awhile

    Joined:
    Apr 15, 2005
    Oddometer:
    795
    Location:
    Jackson , Wyoming
    I just spent the majority of the summer setting up an XR650R , and tryed the Electro sp cra_! They had a cool looking speedo w temp and tach . They never were able to find the right speedo pickup or temp sender. Both F + R brake switch's leaked . Their instructions were as lame as their customer service . The battery nuked the first week and the lights never worked more than an hour . They did take it all back and I think I recived credit two months later . :deal 'guess I'd better check ! K.B. CP how's it handle off road ? I assume it has fuel cell foam inside .
    #29
  10. cpmodem

    cpmodem Orange Caveman

    Joined:
    Nov 29, 2004
    Oddometer:
    7,116
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    Handles fine on or off road. Only caveat, movement of the body to the rear is limited by the tank, so I cool it in soft stuff where I need to get my weight off the front tire. The purpose of the tank isn't for blasting around in the sand anyways. Its for getting there when the stretches are long between points. ie: I used the fuel cell to get me to Elko, NV this summer, then took it off to go play in the dirt for the next few days. Put it back on for the trip home. 5 minute job on/off. I primarily use it for TSD road rallys where time stopped must be kept to a minimum. 11+ gal is the norm in these circles. No foam in the tank, it is fully baffled.
    -cp
    #30
  11. TymeRider

    TymeRider Been here awhile

    Joined:
    Apr 8, 2005
    Oddometer:
    393
    Location:
    Sunnyvale, CA
    To resurrect an old thread...
    and then
    The KTM shop manual gives the following for the stator resistance specifications: Set point value: max 1.0 &#8486;at 20°C

    So why is autorotate's measured resistances (and mine on my 950) that different from the spec?

    When I measure my stator coils (disconnected, pin1-pin2, pin1-pin3, pin2-pin3), I get readings similar to autorotate's, after letting the DVM readings stabilize for about 10 seconds. When I first connect the DVM the reading are 5-10ohm, and within 2-3 seconds they drop to about 0.5 ohms, and then drop consistently until they are 0.1ohm after about 10 seconds.

    I understand this changing value is due to the fact that they are coils and in essence are inductors and so have a voltage drop across each coil that is proportional to the rate of change of the current which screws up the DVM's resistance measurement. But in steady-state (i.e., after 10 seconds) the rate of change of current is zero and the inductive effect will be gone and the measured resistance will be that of the coil. So why is the measured steady-state value (0.1 ohm) so different from the KTM spec (1.0 ohm)?

    Anyone else have resistance measurements on their coils? I'm trying to track down some flaky charging behavior.
    #31
  12. fmfpunk

    fmfpunk Hooligan in training

    Joined:
    Jun 3, 2006
    Oddometer:
    1,191
    Location:
    La Verne, CA
    Bump.

    Anyone had luck finding a place to rewind a 950 stator?

    Thx.
    #32