650/X-2 my stator keeps frying....help

[liquidforce5010]

I am on my 3rd stator and i just finished putting it in and putting my ski back together. I decided to fire it up with the stator cover off and see what happened. I ran for maybe 3-5 sec then turned it off and i noticed there was smoke coming out of the flywheel. I can only assume it is my stator frying again as it did not smell like burning oil smoke. Before i fired it up i ran a battery cable from 1 of my head bolts to my ebox bolt so it would have a ground. On my last two stators the wires were crisped and the copper part of the stator was cooked black. I had someone check everything with a volt meter before i put this stator in and they said everything was fine except for the stator......What could be cooking it...I have to get this ski running for freeride this weekend without frying the current stator....

 

[waterbox]

sounds to me like a ground issue

 

[cljetski]

Email JSS All they do is electrical work

 

[QuickMick]

Talk to WFOspeedracer he works on Kawi's

 

[WFO Speedracer]

No I fix Kawis, I leave the working on stuff to someone else, the first thing you need to know is your starter solenoid was probably installed incorrectly, make sure all the plastic washers, fiber washers, grommets are in there ,in the correct location and that they are good.

Second Kawis have no thermal protection ,aka fuse, before you go any further get a Yamaha fuse holder and install it in the system, this may keep this disaster from happening in the first place. Any short to ground in the electrical box will fry the ground wire to the stator, taking all the other wires and possibly some stator windings with it in the process.

The fuse placed in between the wire coming off the solenoid hot leg and the wiring harness will at least protect that part of the system. However if the solenoid washers are not installed correctly , parts are missing or damaged the solenoid can dead short to the electric box and there goes your stator ground wire.