Stator wires

[Britrick]

Hi, on my 96 xp I'm just trying to remove and clean up the stator , managed to get 2 bolts out without breaking them so that's a start , silly little hex head things! But the actual stator is so seized on the front cover I'm scared of breaking it , any one know a good way to shift it ?
There are 5 wires going to the windings a black and White I believe , very dirty , and 3 yellow sleeved wires to a different point on the windings , on mine only 2 of these yellow ones are connected to the winding the 3rd just terminates there , I thought it had broken but I could find no obvious point from where it had broken , hard to see when it won't come off the cover , anybody know if it should be connected ?
I reakon it would clean up and work hopefully and if I don't have to solder this wire then I won't have to remove it from the front cover and risk breaking something. Thanks

 

[Dr Honda]

all 3 of the yellow wires should be connected to the winding on the stator. So... regardless of if the bolts are corroded... it sounds like it needs to come off, and have a better inspection... and/or... to be replaced.

I would spray it with some penetrating oil, and let it soak a little.

 

[68ragtop]

Like Doc said, all three yellow wires should be connected. There are three charge windings in the stator & one yellow wire is connected to each end of those windings. The other ends are connected to each other commonly within the stator. So if you have an ohm meter you should be able to read 1 Ohm or less between any & all of the three yellow wires.

The other wires should be a ground to the stator & two for the crank position sensor. So I think there should be 6 wires total in the harness, but only 4 to the stator.

 

[Britrick]

Thanks for the replys guys , yeah pretty much expected that , just hoping it wasn't so . All the bolts are out , damn things just siezed itself to the front cover and I'm worried about putting to much leverage on it and breaking either side .
Do Rotax ever grease parts before putting them together !

 

[68ragtop]

Dissimilar metals over time, throw in a in a little corrosion & they try to become one. I would keep soaking it in penetraiting oil, You should be able to put a little pressure under it, if you can stay off the windings?

 

[racerxxx]

If the wire broke off the winding and it is that nasty, you'll be chasing your tail if you try to reconnect it. I do a lot of soldering at my job and am very proficient in it. I wouldn't even bother trying to repair it, if you get a cold solder joint it's going to eventually pop off and ruin a good day of riding. As far as getting the stator off--best of luck, I soaked mine for DAYS. I threw in the towel and bought a front cover with a stator off Ebay for $65 shipped, I know it's going to cost you more being across the pond. I know the availability is limited over there but Minnetonka ships overseas so check with him. If it looks like mine-part ways with it.

From this :

To this for $65

 

[68ragtop]

Holy Shnit balls, that is nastyt :agree:

 

[SabrToothSqrl]

stator

well.. there's your problem

 

[Seadoobuddy]

Where is the "TO THIS" photo?

 

[racerxxx]

Where is the "TO THIS" photo?

It's shows on my screen? Any way here it is again

 

[johngtx]

Is this from age or is this from a engine that has been submerged?

 

[Britrick]

Managed to get the stator off with out breaking anything at last , well exept 2 bolts , I can see where it's broken from now and looks like a right pig to repair sadly , would need a new section of wire with 2 joins . Shame after days of soaking it looked like it would clean up ok .

 

[racerxxx]

Is this from age or is this from a engine that has been submerged?

The one that I pictured was from my XP resto I'm doing. I think it's more from neglect, but if hulls could talk this thing could fill a library!

 

[racerxxx]

Managed to get the stator off with out breaking anything at last , well exept 2 bolts , I can see where it's broken from now and looks like a right pig to repair sadly , would need a new section of wire with 2 joins . Shame after days of soaking it looked like it would clean up ok .

Sorry man, those are the trial and tribulations of a resto. Keep your head up and hammer on, gotta push through the problems.

 

[wip lash]

hello aim kinda new to the jet ski world can some tell me where does the 4 wires coming out of a 94 sea doo xp stator goes connected on the electrical box i have no clue does the black and red wire goes on the coil or the with one thanks

 

[68ragtop]

On the 94 the black with red stripe should go to the coil & MPEM, black is common ground in the ebox. Yellow & yellow black should go to the rectifier for charging.