2001 Road Star- Battery not Charging

[Yamahog12]

I own a 2001 Roadie which I bought new. Recently my battery died while I was riding and testing indicates the battery is not charging. I read an old article by Mr. Tidy on troubleshooting the charging system and I have gone through each step. Step 4 of the article says to test resistance on the stator leads and they should all show .45-.55 ohms. While mine all show the same readings, they are not even close to these values (they are much higher). In fact, I get different ohms readings almost every time I check them. I don't understand why that would happen. I don't mean they change a little, either. They vary a lot, and they are nowhere close to the spec indicated in the article. I also checked continuity from the stator leads to the neg battery terminal and each indicates continuity. I started the bike and checked AC voltage from the stator leads. Each showed nothing. Is it safe to say my stator has failed and must be replaced? I admit that I'm pretty ignorant when it comes to this stuff so feel free to set me straight if I need it! Thanks.

[Lug Nut]

Could be the meter you're using and how it set.But after 21 years and the battery doesn't charge and you've checked everything else out I think I would be pretty okay with putting in a new stator and rectifier at the same time obviously as well as a new battery. I would upgrade to the 2005 model because it's higher output. It's not a bad job just have to jack the bike up remove the lower exhaust and floorboard and the gasket is a pain to scrape off of the stator area of the engine.

[Yamahog12]

I went to Partzilla.com as they seem to have the best prices on parts. First- I just would like to ask you if you are sure the stator for a 2005 Road Star will fit in my 2001. I've read that it will but wonder if you know that for certain-?

On the parts diagram for the stator there's another part called a pickup assembly. It looks like the wiring coming off the stator but it shows as a separate part. In my Yamaha service manual there isn't anything shown in the diagram called a pickup assembly. It looks like the wiring coming off the stator is just part of the stator. Is the 'pickup assembly" something separate from the stator or is it the actual wiring that comes off the coils? If I buy the 2005 stator and I have to re-use the wiring, will the wiring from my 2001 work with the 2005 stator?

[Yamahog12]

Thanks, Lug Nut. I found an old RSC article on changing out the stator, but none of the pictures in the article will show. I find pictures to be extremely helpful when I dive into something I have not done before. Do you of a how-to that includes pictures of the process along the way? Thank you.

[Father Pobasturd]

Most of the pics from the old RSC site did not transfer to this new site. Unfortunate but nonetheless, there it is. What I find amazing is you've had this bike 21 years and only now have come to this site. There's a testimonial to Roadstar reliability if ever I saw one.

[Yamahog12]

Pobasturd- I agree, although I have visited the RSC site a few times. I just now joined, though.

[Lug Nut]

Thanks, Lug Nut. I found an old RSC article on changing out the stator, but none of the pictures in the article will show. I find pictures to be extremely helpful when I dive into something I have not done before. Do you of a how-to that includes pictures of the process along the way? Thank you.

Not other than the manual.

[Yamahog12]

Yeah I have the service manual but it's nice to have actual photos of what is being described in the article. I'll do it regardless, but I'll take any help I can get.

[Ahodge75]

I’m sure someone on here has those pics saved from the old forum. I did mine when it was still up so I did not think about saving the post at that time. It’s not difficult to do but agree I like having pics to look at along the way also.

[roadiemort]

http://www.roadstarmagazine.com/2002...arging-system/

[roadiemort]

My piece of the Magnetawan River.

[Yamahog12]

Nice spot on the river!

Thank you for that link. I already have this and that's what I followed to determine I need a new stator. On the old RSC there is a how-to on changing out the stator. It is very detailed but the pictures that were embedded within the text do not open anymore. This is the article https://wayback.archive-it.org/10073.../view/189/103/

[roadiemort]

A Clymers manual has more actual pictures than the Yamaha manual does. Can't help you with the missing pics from the link though.

[brianmac]

[Yamahog12]

I've been researching the process of replacing the stator, and getting some parts prices. In the Mr. Tidy article on doing this, he recommends Fixing the Starter Spin Problem since the generator cover will be off. I read through that process and, honestly, it looks like more than I would be comfortable trying. How prevalent is the issue this is designed to fix (or prevent)? Has anyone here experienced the failure of the rotor coming loose from the shaft? Thanks in advance for your input.

[davej]

It is not that common of an issue. I am comfortable doing things mechanical and I wouldn't do it. IMO if you try to fix something that is currently a non issue and not a common issue you are just asking for trouble.

[Yamahog12]

Davej- thanks for your response. Ride safe.

[Ratl]

…Step 4 of the article says to test resistance on the stator leads and they should all show .45-.55 ohms. While mine all show the same readings, they are not even close to these values (they are much higher). In fact, I get different ohms readings almost every time I check them. I don't understand why that would happen. I don't mean they change a little, either. They vary a lot, and they are nowhere close to the spec indicated in the article...

I recommend cleaning the leads and all connections with fine sandpaper, as well as the tester leads, then re-checking your readings. Much higher readings would indicate a fault in the circuit, but I would expect consistent readings, which is why I recommend the cleaning and re-checking. Age and corrosion play havoc with electrical connections.

It’s a cheap and easy thing to try and could be all you actually end up needing to do. If not, it didn’t cost you anything to try.

Ratl.

[Yamahog12]

I will definitely try that before I get into anything more invasive. Thanks.

[Yamahog12]

Hi all. As the weather starts to warm up a little, I am thinking about my 2001 Road Star project. I must remove the front exhaust pipe to access the generator cover and it has been many years since I have taken the pipes off. I have V&H Longshots and I'm sure the muffler is very tightly connected to the pipe, and I know the heat shield (held on with hose clamps) is probably going to be very difficult to separate. The entire thing is connected to the bike in 2 places: obviously at the exhaust flange and with 2 bolts to a bracket towards the rear. I am wondering if it is possible to remove the pipe, muffler and heat shield all in "one piece" and then reattach the same way. Because it has been so long since I have removed the pipes, I don't recall exactly how the pipe attaches to the exhaust port except that I'll replace the gasket and there's two chrome hex nuts going into the flange. Has anyone here removed an exhaust pipe, muffler and heat shield as one unit? Thanks.

[Brad_G]

I'd spray some penetrant in the hex of the exhaust studs and near the flanges and let it sit for a couple days if possible. Might help make those easier to remove. Most likely have to at a minimum loosen the floorboard mount. I had a semi stripped hex head bolt for the board mount so I opted to just pull the floorboard pin and that was sufficient to allow me to work on my exhaust.

[Yamahog12]

Brad- That was good advice. I was able to remove everything as a unit. Hopefully it will go back on just as easily. Thanks.

[Yamahog12]

Yesterday I tied kite string to the stator connector on the left side of the bike and tried to pull the cable down through and over to the right side. So far I cannot get it to go through as it hangs up on something and I can't reach it. I could cut off the connector and it will come through but I cannot see how I will get the new one to go up through and over to the left side. I've thought I could maybe cut off connector on the new one, pull the wires up through and attach the connector again. Can these connectors be reused? If not, where might I find the exact new connector? Thank you.

[Shores]

I'm not familiar with the wire you are speaking of but most connectors can be removed from the wires without actually cutting the wires. Look inside where the wires enter the connector and there should be a little lever that you press with a small screwdriver or other tool to release the wire.

[Yamahog12]

I didn’t know that. I’ll see if that’s possible. Thank you.

[Brad_G]

Yesterday I tied kite string to the stator connector on the left side of the bike and tried to pull the cable down through and over to the right side. So far I cannot get it to go through as it hangs up on something and I can't reach it. I could cut off the connector and it will come through but I cannot see how I will get the new one to go up through and over to the left side. I've thought I could maybe cut off connector on the new one, pull the wires up through and attach the connector again. Can these connectors be reused? If not, where might I find the exact new connector? Thank you.

I can't comment directly to what you're attempting to do. Typically the connectors I've worked with have a release and the wire and terminal "should" be able to be removed from the connector. That may reduce the overall size and allow you to feed it through. If I were doing that I'd put a mark with a Sharpie with either a 1, 2, 3, etc. or 1 dot 2 dots.... and make a drawing of position of how they came out of the connector to make sure they go back in the same respective spots (presuming this is important).

Use your kite string or other means and pull through when removing the old wires to connect to the new and draw back through.

So far, all of the connectors I've needed for my '03 1600 and '08 1700 projects I've found at http://www.cycleterminal.com/index.html along with crimping and release tools.

None of this answers your question directly but hopefully provides some food for thought.

Good luck and let us know how things go.

[Yamahog12]

That’s very helpful information and a good idea as far as marking wires to be sure to put them back into the connector correctly. Thank you.

[Mr. Miyagi]

The connections shouldn't matter, the stator makes a three phase ac current that is changed to dc.

[Shores]

That’s very helpful information and a good idea as far as marking wires to be sure to put them back into the connector correctly. Thank you.

Or just take a couple good photos with your phone.

[Brad_G]

Phone pics are a great idea as well and I've done that too. For some reason I'm thinking that the stator connection the wires may all be white (forget where I came to that conclusion) which would make me think positioning isn't important. But I'd rather be safe than sorry.

[Yamahog12]

Shores and Brad G.- Thank you again for the tip. I was able to pull the wires from the connector and then pull them through to the right side of the bike. Very helpful.

[Brad_G]

Good to hear. I myself like to put a little electrical contact grease in the plugs to help keep moisture out. It also makes them easier to unplug if it's something like the rear fender connection that may get used more frequently.

[brianmac]

that connector is a PIA , i have cut off the sharp edges, and taped it to try to get it thru no mans land used bare copper ground wire bent into a hook.

[Yamahog12]

It is! But surprisingly I was able to get the new one to go up and through to the other side with ease.

[Lug Nut]

Thanks, Lug Nut. I found an old RSC article on changing out the stator, but none of the pictures in the article will show. I find pictures to be extremely helpful when I dive into something I have not done before. Do you of a how-to that includes pictures of the process along the way? Thank you.

Video on you tube for stator replacement on a Road Star

[Yamahog12]

I found one but it wasn’t very detailed at all.

[Yamahog12]

To follow up, I got the new stator and reg/rectifier installed and I’m back in business. Thanks for all the advice and helpful tips.

[Brad_G]

Glad to hear you're back on the road.