Distance the stator is offset from the crankcase?

[evoluzione750]

Riding season has arrived, so I'm back at trying to fix this pile of junk. I've posted on other forums, so hopefully I can find an answer to what has been causing me so much grief or helps somebody else with the same problem. This is a bit of an odd question, but does anybody know the distance the stator is supposed to sit offset from the crankcase? I don't know if the crankcase on my bike has been modified at all, because when I bolt the stator flush to the crankcase, it looks like it isn't completely surrounded by the magnet. I thought this couldn't be correct, so I've offset the stator about 1/4" with a couple of small washers on the backside of the stator so it's more enclosed by the magnet, taking care to not let it cause a short between the stator windings and the crankcase.

I need to know because I've been having a charging issue that I cannot solve. I've replaced the reg/rec with a brand new R6 spec model. In order to narrow down if the problem is within the loom, I've set it up so the loom is bypassed entirely, just separate wires running directly from the stator to the reg/rec, then directly through a main fuse to the battery.

After testing this setup, it still won't charge. The battery shows about 12.5v when revved to 3k. Putting the meter on the stator output connector, it's only showing around 1v AC on all three phases. The stator is a used, OEM unit I bought off eBay and I just got it rebuilt at Rick's Motorsport Electrics, so I'm reluctant to say the stator itself is bad. I have no other ideas for what could be causing the problem, other than by some strange reason the magnet in the flywheel has somehow gone bad, but I seriously doubt that it's the problem.

The bike is a stock, 1988 1WG 3EN1 model (imported) if it helps.

When looking at a mirror, this is how the stator sits inside the flywheel when offset with the washers. It looks like the back edge of the stator is about flush with where the magnet starts in the flywheel, as there is about an 1/8" of material before the magnet starts.


Does this look kosher?


Without the washers between the stator and the crankcase, the distance from the front of the stator at about the 12:30 position is about 1.68 inches to the case and about 1.02 inches from the back of the stator to the case. The three mounting bolts bottom out before they actually start to hold the stator on the case when I mount it without the washers behind it, hence the washers under the heads of the mounting bolts.


This is how the stator sits in the flywheel without the washers between in and the crankcase. I don't believe the windings are fully enclosed by the magnet, It looks like the back edge of the stator is about flush with the edge of the flywheel.


Thanks gents

[Evilchicken0]

Inches ... that's so last century Hello American welcome to the forum.

Don't think I've ever had this query before. Firstly the reg recs on these aren't so bad that you'd really need to fit the R6 reg rec.
The quickest way around this is to get another alternator and fit it up. It maybe you have the wrong type of alternator from a different model fzr, yours should be common with a fzr600 3he. If this next one works then you know yours is duff it not you know there must be a problem in how you're fitting it.

[evoluzione750]

Haha, we'll make the switch someday...but today is not that day. :D

The stator I bought was off an American market FZR 400, but I was under the impression that it was a shared part amongst all the 1WG models.

I'll try spacing the stator even further into the flywheel and see if it makes a difference, because it looks like there is plenty of room left, about a good 3/4" (or should I say about 2cm?).

If it doesn't work, I may have to look into getting a 3HE stator, as you said. Are the Caltric units to be avoided? They seem bargain priced for brand new.

[evoluzione750]

Moving the stator in increased the output by a whopping one volt! Seriously, I have no idea what else could be wrong. I may have to look into getting another stator for this thing.

[dobbslc]

That rotor should have a magnet strong enough to stick a screwdriver to it VERY firmly, if I remember correctly they can be a bitch to put over the stator as they try to pull themselves in, mind your fingers king of strong!
How good it your magnet? Any cracks in it?
Can you test the rewound stator coils with multimeter?

[Evilchicken0]

There's nothing wrong with the R6 reg rec at all but there isn't much wrong with the 3en one either especially if they're cheap.

I'd get another stator off a fzr600 around the 88 to 90 period. The usa market 3bf is a bit of a parts bin special, I'm not sure which model the engine comes from.

[evoluzione750]

The magnet feels strong enough. If I drop the stator in the flywheel when they're both off the bike, it's near impossible to pull it out, if that's any indication of the magnet's strength.

The meter tells me the resistances of the three phases are 0.4, 0.5, and 0.5 ohms, and no shorts to the crankcase.

I've tested using both the old, four pin reg/rec and the R6 reg/rec, and it makes no difference. Diode tests on both of them check out, so as far as I can tell, neither one is defective.

Would something like this be an appropriate replacement? The model years listed are for the 600's of 1989, 1990, and 1992.
http://www.ebay.com/itm/STATOR-GASKET-F ... ln&vxp=mtr

The replacement stator on the bike didn't have any part number stamped on it, but the part number on the flywheel is FL118-09. From the 3EN2 parts manual, which I think shares most parts with the 3EN1, the flywheel and stator part numbers are 1WG-81450-10 and 1WG-81410-10, respectively. Could the flywheel be wrong on my bike? The only instances I can find of a FL118-09 are for another 400 flywheel for sale in Australia (doesn't list the year) and for a 3HE 600 flywheel.

Is there any theoretical reason why the American market 3BF stator wouldn't work with the flywheel used in non-3BF models like the one I have on the bike currently? Otherwise, I've got to play an expensive game of mix and match to find what works. From what I've researched, the 3BF flywheel has FL118-13 stamped on it, while I assume the flywheel for non-3BF is stamped with FL118-09. If they can't work together, than I'll have to look into either getting a 3BF flywheel or finding the stator that fits the 3EN1, of which I cannot find any identifying features needed to find one. I don't know if I mentioned it earlier, but the stator that was on the bike when I bought it was a 13 pole, so not at all what it needed, so that's why I bought the replacement.

Flywheel from an American market bike, you can just barely make out FL118-13
http://www.ebay.com/itm/88-Yamaha-FZR40 ... qK&vxp=mtr
This one states that it is off a 3BF model, a bit easier to see the FL118-13
http://www.ebay.de/itm/E-Yamaha-FZR-400 ... 1392560561