stator problems - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 6 Old 11-16-2008, 09:43 PM Thread Starter
Join Date: Nov 2008
Posts: 3
stator problems

hello all,
Nice site,lots of good info and stories, I've viewed several times but just now joined.
Does anyone have any thoughts on a 1989 klr that blows the stator after a few miles. The firs time this happened the battery had shorted out, and I think this may have killed the stator. I replaced the stator with an Electrosport stator and rectifier regulator, It lasted about 300 miles. Repair # 2 was with OEM parts, they failed as well. The bike is in good condition and has 14 k miles on it. Everything seems ok with the bike no blown fuses on shorted wire nothing looks melted.
I have un taped all the wires, looking for shorts, but have found no problems.
I am at my witts end and have parked the bike for now at least. It is now winter where I live, so if I can get it running over the winter I would retag it next summer. Any thought or ideas would sure help.
Many thanks to anyone who answers,
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post #2 of 6 Old 11-22-2008, 11:02 PM
Join Date: Jun 2008
Posts: 11
I'm new to the KLRs so I don't know them well yet, but I do know a little about stators from the old goldwings and suzukis. It sounds like you are either still looking for a short or more likely a connector that is corroded or weak that causes severe impedance. Either condition will cause the stator to work constantly and then burn out. On the older wings, there was a connector that would corrode over time and many people just cut the connector out of the system. The 80s susukis used to run the charging circuit through a handlebar switch that caused problems because of impedance. Anyway, I'm very confident that you have a connection issue or a short that is causing the stator to work itself to death.

Hope this helps
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post #3 of 6 Old 11-23-2008, 12:06 AM Thread Starter
Join Date: Nov 2008
Posts: 3
thanks for the input

Many thanks for the input! I at least don't feel ignored anymore.
I wondered about this, when the 2nd stator burned out. I asked the other electronics tech that I work to help me look it over real good the last time I replace the stator. He found nothing out of line, we untaped the whole wiring harness and looked over everything.
If you see a KLR engine on ebay from Kansas “that runs good but wont charge the battery” DON’T BID!
I have just about decided to part it out, and sell the pieces on ebay.
Parts seem to sell good and it has lots of parts that are still good. I would'nt feel right selling the whole bike, and screwing someone.
I love the bike but this is the 3rd kawasaki I have owned and they have all cost me a lot in parts. I presently have 6 vintage Honda bikes in my collection. All 25 plus years old, and all bikes are dependable and have little trouble. I ride a different one, about every day or so to work.
I sure like this bike but have just had my fill of it.
Well thats my rant, sorry to vent.
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post #4 of 6 Old 11-23-2008, 12:13 PM
Join Date: Jun 2008
Posts: 11
Sorry that it came to that for you, but I understand. That has been my experience with susuki. So far, I love my KLR, but I have always had Hondas and never been disappointed by one since 1968.
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post #5 of 6 Old 12-10-2008, 06:18 AM
1st Gear
Join Date: Sep 2008
Location: Texas Panhandle
Posts: 97
Have you checked the regulator/rectifier? I didn't see it mentioned. A faulty regulator/rectifier could do what you described.

Last edited by ScareCrow; 12-10-2008 at 06:37 AM.
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post #6 of 6 Old 12-29-2008, 08:41 PM Thread Starter
Join Date: Nov 2008
Posts: 3

The regulator is ok? from what I can tell. I have a replacement and an OEM, both seem to test the same. I tested them useing the instructions in my shop manual. I have been working on this bike some this winter, looking for bad connections and such as was suggested by some of the guys on this forum. Man, I just can't seem to find anything wrong. I am sure tired of buying new part only to have them fail. Mayby I should take it to a dealer and have it fixed. I would like to sell it, but would'nt feel right about selling someone a lemon. Been thinking about just listing it as is and disclose the troubles, see what shakes out.
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