Switched out stator...still having a problem

[Woody]

Hi,

So I have an 06 SJ with a decent amt of mods, but I also have a 650sx that I keep around for the friends (stock). Anyhow, plugged in the battery after being in all the winter...fired up...cleared out all the fogging oil, then shut her down.

About 5 seconds after I shut it off, it started smoking like crazy from inside the motor. I immediately unplugged the battery...left the motor for a day then went back to take a look at the damage.

The wire from the ebox that reads "magneto" is all burnt up and fried. I want to fix this thing up so I can get rid of it, so if someone can help me figure out what is wrong with it, what i need to fix it, and how i can go about fixing it that would be great.

on a scale of 1-10 of mechanical skill, i'd say i'm a 4 with a 10 being able to bore motors and a 1 not being able to use a screwdriver. so...can anybody tell me...is this an easy fix? if not is it a cheap fix the local jetski mechanic can do? or is it just worth it to cut my losses and try to sell it for the best offer?

EDIT: SEE POST #10 for more detail!!!

thanks all.

yellow wires on the right side of the ebox

actual wire

 

[QuickMick]

start peeling back some of the char and see if there is a cut wire in that area. go to the kawi board and post, you might get a good bite.

 

[Woody]

ur saying see which actual wire fried?

 

[sflsurfrider]

probably the black wire is burnt.

 

[Woody]

the ground wire...thats what i was thinking too. how do i fix it just replace the whole piece?

 

[sflsurfrider]

its been a while since ive seena toasted stator ground, but as i recall, you can just run a new separate wire.

the cause is eluding me too. i think it has something to do with a crappy main ground from the battery to the block.

 

[Woody]

ok. the copper wire is showing through the plastic though...thats ok?

 

[Pro-pulsion]

What year is the ski? I'm looking at the wiring diagram for a 92-93 650SX and there should only be a black/yellow which is a ground, purple which goes to the CDI, and 2 browns that go to the voltage regulator. Can you peel back the black harness sheath and expose the internal wire colors, then post back what they are? I would also check inside the electrical box and see if anything in there melted like the voltage regulator. Usually if an electronic component melts it will swell or where you see the wires go into the component you will see bubbles from the melting. Check that stuff and post pics of anything you think might look damaged. If for whatever reason the stator shorted out and needs to be replaced, there's a place not far from here that rebuilds them for about 250 bucks U.S. I had it done for my Sea-Couch and they do a great job. Here's the link to them actually....

http://www.rmstator.com/en/index.htm

 

[Woody]

i will start cutting back the wire tomorrow midday. i was looking at this diagram though:

 

[Woody]

ok...opened up the ebox and cut back some of the char on the stator wire. the BLACK/YELLOW wire from the magneto wire to the connection of the regulator rectifier is completely gone...just ash and some random strands of copper wire. However, the black and yellow wire after the connection that actually hooks up into to the regulator/rectifire is completely ok...no damage. i looked pretty carefully, and i did not see any other damage to any other components or wires within the ebox or cdi.

there is some other damage to the BLACK wire also...but you can see this is clearly heat damage from the BLACK/YELLOW wire melting.

i'm assuming that because there is so much damage to the BL/YL wire i'm gonna have to replace the entire thing?

here is the connection of the stator wire to the reg/rec. notice no damage after the connection.

here is the actual stator wire with some char cut back. as you can see only four wires as one is fully burnt out.

 

[Conquistador]

I'd replace it for sure, but maybe a secondary ground wire from the ebox to the motor will help too. I did it with the 550 motor & the 750 motor and many others do it with sjs. I've burn't wires from the inside out in the past, but none since I've added a second ground.

 

[QuickMick]

Maybe you should think about calling John at JSS and quiz him on it and maybe even have him rewire the thing.
Im thinking if you dont find out why that thing melted it might happen again.
Out of every problem that comes up with ski problems. I hate electrical problems the most.

 

[Woody]

ok thanks guys. so i pulled the motor, i'm def. gonna need to get the stator repaired or replaced. i'm still wondering why this happened in the first place after being winterized all year. now that the motor is out, how hard is it to replace the stator? i'm nervous about getting myself involved too deep and then screwing up the timing or something when i pull the flywheel.

here are some more pics of the ebox and cdi...the wires look good still right? could anything else have been shorted when this wire was burning up?

 

[Pro-pulsion]

Test the stator, it's easy to do and the service manual will tell you how to test it. But I would think that given the ground wire is burn up that badly, there has to be a short in the stator.The ground wire is basically just acting as a fuse core now and because it has the least amount of resistance to complete the short, it took the abuse.

 

[hellcat66]

hey woody, i would R &R that bitch if it were mine...i think jetski solutions will rework it for you also. you can get it out you just need a puller set with a slide hammer and a 6pk... i have a good mint stator but i think i need to keep it for a spare in case this happens to me...sux that happened to ya but there had to be a short somewhere and you never could have seen it coming...good luck

 

[Woody]

so i had another 650 stator that i switched into the ski...put the motor back in etc. put all the wires back together, and when i went to hook up the battery, i started to cook the wires again. i'm assuming that i have a + touching a - somewhere along the line.

any suggestions on where to look? could the start/stop solenoid have some kind of short in it where its giving juice to the metal e-box where everything is grounded?

 

[Pro-pulsion]

Either that or the voltage regulator. It is possible too, that if it's an old stator you put back in place of the burnt one that it's defective too.

 

[ANT]

Either that or the voltage regulator. It is possible too, that if it's an old stator you put back in place of the burnt one that it's defective too.

if the voltage regulator was bad it would still spark, it just chrages the battery. If you put in a new stator, and your ski is in a garage turn out the lights and see if you can see spark cause the 650's have a weak spark initially and it is hard to see. Next thing you could try is to cut back the plug wires a little they can corode. If you just tryed replacing the ground wire, the stator coil is probably bad. You can actually buy them individually, I've done that before and it works. you should resort to reading for resistance and voltage output from a manual so you dont waste a bunch of time.

 

[Woody]

forget about not getting a spark.....

i'm not even getting it to turn over!! when connecting the starter cable directly to the battery it turns over

its something in the ebox. i have an entire new (used) one coming next week. does the cdi control anything except the spark?

 

[ronrymanr1]

if the voltage regulator was bad it would still spark, it just chrages the battery. If you put in a new stator, and your ski is in a garage turn out the lights and see if you can see spark cause the 650's have a weak spark initially and it is hard to see. Next thing you could try is to cut back the plug wires a little they can corode. If you just tryed replacing the ground wire, the stator coil is probably bad. You can actually buy them individually, I've done that before and it works. you should resort to reading for resistance and voltage output from a manual so you dont waste a bunch of time.

If it's stator grounding itself, it's a waste to try replacing grounding connection?Ohms readings show red and black wire & yellow black readings ŵith same the readings as each one to engine block? E box all checks out no Sparks? Question is a stator from a big pin 750 simular as a js650sx stator? Old thread I have faith.

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