ok. so, i have been going through things in an engine rebuild of my 67 dream 305. the previous owner had worked on the starter clutch....he told me when he first started it up there was a "clunk"....but told me later that he had fixed the problem. upon disassembly of the rotor and stator, i discovered that a chunk of something (maybe the pin that holds the roller in the starter clutch?) had gotten trapped between the rotor and stator and broken off within one of the stator windings...like a little bullet! kinda cute. anyway, the rotor seems pretty ok, a little scratched in one spot but no big deal. however.....
i should add that things seemed to be working ok before the teardown, though i honestly never checked stator output/charging. but the battery did hold its charge for the limited riding i did on her, maybe 75 miles total.
ok, so i tried to remove the "bullet" from the winding, and i think i made things worse....now the chunk of metal is kind of hanging out more than it was...AND, i cracked some of the insulation off the winding. so, my question is, is this terminal for my stator, do ya think? seems they are reasonably available used on ebay, anything to watch out for in picking one up? anyone here got a decent spare around?
pics to follow....
and, thanks!!
greg
new stator time?
ok, here we go...
 and a close up you can see the cylindrical bullet kind of sitting in there...ugh.,  its not like the stator is hard to get to, maybe i should just install it and see what i have? worried about that insulation missing more than anything. ugh. well, a used one only seems to be like 40 bucks or so....whaddya think?? greg Greg, high temp silicone over the bare wires, and like you said, it's easy enough to re-assemble and try it out. Used ones are readily available. If you have an ohm meter, check pink, brown and yellow one at a time the other end to stator body. There should be no continuity. Next check the same three wire against each other, and all should have the same continuity readings.
davomoto
or, i could just break it. decided to take the windings out of the aluminum housing, and in the process the insulation on the wires from the windings to the output wires completely disintegrated. ah, well. i have a while to think about how to deal with it.....do i get a used stator or maybe spring for that new unit from ricks? well, lots more to do before i get to that. thanks guys!
greg
not sure about the bare wires...i see on the rick's unit the wires are left bare anyway...i think the wrapping is mainly to keep everything in it's place. unfortunately, one of my wires also broke (effortlessly, i might add, as though it were already partially cut or maybe really brittle? ) wonder if i could solder it back? but then again, 40 bucks will get me a used replacement, money well spent i would think..
thinking about this has made me wonder....has anyone here attempted rewinding their own stator? on the other forum i am on there has been some experimentation with this, with some success....i need to do some homework here i guess on the diff between the stock stator, the ricks unit, and my suzuki stator in terms of how they are wound, output, etc.
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