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Charging

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wiggy2146 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote wiggy2146 Quote  Post ReplyReply Direct Link To This Post Topic: Charging
    Posted: 15 Mar 2018 at 09:26
hi folks, have a problem with my gen2 07, figured it is the generator it's totally fried 6v on two phases 3v on another , but I'm getting different options, either, buy secondhand, rewind the stator, or its the rotor causing the burnout complete new unit but thats£££££. Help if you can.
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Spoonz View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 15 Mar 2018 at 10:14
Quite possible that the Stator is toast but those readings are not right. Each phase should have about 50-60v AC and it's very unlikely that all 3 phases are down completely at the same time. You did measure on AC volts and not DC, and stator not connected to the Reg/rec (in case it's pulling the stator down although unlikely)?
 
If the stator is down, you have 2 choices. Fit another stator and hope that the flywheel isn't the cause as it will burn out aqain fairly quickly. Or fit the 380w stator/flywheel kit which is expensive but will deffo not do it again. There is no easy way to determine that your flywheel is the cause so it's a gamble if you don't replace it.
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badapple View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 16 Mar 2018 at 02:57
Im currently dealing with this myself. Ive sent my stator to West country windings and they called me today to confirm that its burnt out and will be back by Saturday/Monday so I'll be putting it all back together early next week and I'll report back.....fingers firmly crossed!!!
I started out with nothing and I've still got most of it left
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tapmyhed View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2018 at 14:22
Its a horrendous regular issue with these engines.  Spoonz spot on with the generator as the cause.
Windings get very hot in use.  No cooling, they always burn out at the top.

There are a few ways round this, some good some average, but no real 'cure'.  the cure is they dont get hot, or hot enough to challenge the insulation used.

What have I done (yeah I did something):

1. Get rid of brown connectors, cut them out - solder and crimp cables.
2. Get rid of white connector under seat.
3. Separate charging from supply and fuse accordingly.
4. Get the ECU live feed and put it through its own 5A fused supply from the battery.  It comes off the 30A, so if that blows, your broken down.  It could blow if the stator fries to earth.  at least with a seperate supply, you can pull the head light connectors and still get home.  This worked for me once.
5. Change the regrec for a shin series type.  About £120, but manages the stator load better.  Not a complete solution, but an improvement .
6. Sort your earths out, John Walker leads are the nuts.
7. Oil cool your stator.  A couple of solutions here.  You can buy a T10 kit that takes a feed from the oil cooler and feeds it into the sight nut in the middle of the gen cover.  I thought this was agricultural as a solution.  I modified the filter cover to give me a pressured feed through a short brake line, via a restrictor (NOS jet) to give me 100mls a minute, and drilled a connector right at the top of the gen cover to point the oil flow right at the top of the stator windings.  I also changes the oil pump spring for the original stiffer one and run the oil pump at 5.75bar.  Works for me.  Parts cost £25!  A few hours careful drilling and tapping.....oh and the oil pump...not so simple, but I was changing the clutch anyway.

Its a sh*t problem on the Gen2s.  Save the hassle and change the flywheel.....I liked the challenge of alternative cooling!
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tapmyhed View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote tapmyhed Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2018 at 14:27
I built a big bore engine from an engine with 1500miles on it.  Even that stator had browned, but was good.  My old one off the old engine had browned too, but that had done 20K miles since the last fry and I had the mosfet regrec on it....so it was going to go eventually, which is the point....most solutions will slow it down a bit, oil cooling should stop it....if it doesn't get hot, its not going to burn???

but the right solution, and on the back of Griffs hard work resolving this, is a weaker flywheel and a thick wired stator.

I sometimes think heat is OK if nothing burns, and the thing that burns is the insulation.  I dont know why copper wire can not be specced with better insulation, almost a ceramic based insulation.....but what do I know? I think standard stator winding is rated to 250C??? So its got to get bloody hot really to burn that!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2018 at 15:28
The 380w stator/flywheel kit is an official Aprilia solution and was oem on post 2008 bikes. It's in the Aprilia parts fiche and has been available to any dealer since it's introduction. It's become more accessable now because of a major price drop from Aprilia (less than half what it was)

If you look at almost every burnt out stator, the burnt area is above the oil bath level. Which suggests the oil mod might work and that Rotax over estimated the spray effect on the upper section of the stator.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 19 Mar 2018 at 16:47
Originally posted by tapmyhed tapmyhed wrote:

I built a big bore engine from an engine with 1500miles on it.  Even that stator had browned, but was good.  My old one off the old engine had browned too, but that had done 20K miles since the last fry and I had the mosfet regrec on it....so it was going to go eventually, which is the point....most solutions will slow it down a bit, oil cooling should stop it....if it doesn't get hot, its not going to burn???

but the right solution, and on the back of Griffs hard work resolving this, is a weaker flywheel and a thick wired stator.

I sometimes think heat is OK if nothing burns, and the thing that burns is the insulation.  I dont know why copper wire can not be specced with better insulation, almost a ceramic based insulation.....but what do I know? I think standard stator winding is rated to 250C??? So its got to get bloody hot really to burn that!
I'll be sending you a pm this evening for a bit more information if thats ok. Im not far from you I'm based in Norwich.
I started out with nothing and I've still got most of it left
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