New stator wiring - Kawasaki KLR 650 Forum
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post #1 of 8 Old 12-26-2018, 09:57 AM Thread Starter
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New stator wiring

Hey everyone, merry christmas!

I've had a 84 600 For about 10 years now and I'm fitting a new stator which isn't plug and play. Electrics is my downfall and I was hoping to get some insight on hooking it up. The original has 4 wires, 2 yellow which go to the regulator, blk/w to the ignition switch and a red to the Cdi. The new stator has 5 wires, red brown and 3 whites. Am I right in thinking that red and brown go to regulator? Also what do I do with the extra white cable? Any help would be greatly appreciated thanks
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post #2 of 8 Old 12-26-2018, 10:03 AM Thread Starter
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Here's a pic
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post #3 of 8 Old 12-26-2018, 01:17 PM
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post #4 of 8 Old 12-26-2018, 03:50 PM
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OK, that dog ain't gonna hunt too well.

All KLRs, 1985 to 2018, have a three-phase alternator. The stators are wound in an 18-coil format with three sets of six coils (there are phantom coils '85 to '07 where the two exciter coils are, but electrically it is built as if the three missing coils were there). Those three sets are, electrically, offset by 120 degrees. Thus the 'three-phase alternator'. They are wound with a "Y" configuration with the three wires coming out and going to the rectifier/regulator.

What does all of that mean to you?

You have an '84, which was the only KLR that was kick-start only and the only KLR that was built with a single-phase alternator. It is built as a 12-coil stator with all 12 coils wound in series, thus it only has two wires to go to the rectifier/regulator.

I think you can make it work by installing a three-phase regulator/rectifier. The 21066-1038 that was used '85 to '07 is an OK unit.

The '84 rotor is unique also, so there's no way you can swap in a later rotor and have it work. However, it has 12 magnetic poles just as you would expect ti to. Magically and mystically, the later rotors also seem to have 12 poles (though my impoverished education would have led me to believe that an 18 coil three-phase alternator would need 6 poles) so I think that the '84 rotor will work with a three-phase stator.

That's two "I thinks" coming from a guy who prefers "I know" or at least "I'm pretty damn sure", so you'll have to try it to find out. I'm going to be trying it soon.
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Last edited by Tom Schmitz; 12-26-2018 at 03:53 PM.
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post #5 of 8 Old 12-26-2018, 04:20 PM
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i actually reckon it will work if you just hook up 2 of the 3 phase tails, you just wont get as much power and likely work as a half wave rectifier.

but otherwise at tom said you can get a 3 phase regulator.

Last edited by Roy Russell; 12-26-2018 at 04:22 PM.
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post #6 of 8 Old 12-27-2018, 11:03 AM Thread Starter
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Thanks for the help chaps, tom very insightful!! I'll give it a whirl tomorrow
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post #7 of 8 Old 12-27-2018, 11:55 AM
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I'm getting close to "Pretty damn sure" on the rotor issue.

Going back over what I learned 40 years ago, my mistake was that my recollection was faulty re the 'three coils per magnet' concept. It is 'three coils per magnet pair' and with 12 magnets (poles) I'm now pretty damn sure that the '84 rotor will work in a three-phase system.

If your Loo Library is lacking 'lectrifying literature you might find this work-in-progress interesting: https://souperdoo.com/stuff%20that%2...ces-in-my-shed and this unpublished article :https://www.souperdoo.com/stuff%20th...nges-over-time<<Currently switched off; unpublished for now...

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Sting like a butterfly.

Last edited by Tom Schmitz; 12-27-2018 at 11:28 PM. Reason: Can't link to an unpublished article. Rats.
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post #8 of 8 Old 12-27-2018, 04:50 PM
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Quote:
Originally Posted by Tom Schmitz View Post
OK, that dog ain't gonna hunt too well.

All KLRs, 1985 to 2018, have a three-phase alternator. The stators are wound in an 18-coil format with three sets of six coils (there are phantom coils '85 to '07 where the two exciter coils are, but electrically it is built as if the three missing coils were there). Those three sets are, electrically, offset by 120 degrees. Thus the 'three-phase alternator'. They are wound with a "Y" configuration with the three wires coming out and going to the rectifier/regulator.

What does all of that mean to you?

You have an '84, which was the only KLR that was kick-start only and the only KLR that was built with a single-phase alternator.
The kick-start only KLR250 (produced through 2005 model year) has a single-phase alternator charging its battery; two yellow wires from the alternator to the regulator/rectifier. Same with the KLR600, according to the Kawasaki Service Manual. With the OP's stator, he might make a kind of Frankenstator by wiring two of the three yellow wires together; alternately, he can just choose two and leave one disconnected (but taped).

No biggie either way, I think, because . . . the kick-start only bikes only charge the battery to activate lights when engine is dead; no high-current starter demands.

Haven't checked part numbers, but . . . I imagine possibly KLR250 and KLR600 ignition parts are interchangeable; must be a KLR250 or two a-moldering in some "dismantler's" (motorcycle junk man's) inventory somewhere with a functioning stator.
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