I appreciate your help. Sorry for the delay I got burried at work and frustrated with the bike. Got a new stator and new regulator. As I was putting it all back together I thought I should double check the rotor. After all - "rotors never go bad unless they throw a magnet and then its a catastrophic failure". I look at the inside of the rotor and a magnet is missing. How can that happen without destroying the stator? A closer look and 5 of the magnets had come un-glued and slid together. Without the gaps, they were not creating the multiple fields to generate juice. This was causing the intermittent charging in my original e-mail.

New rotor, stator & regulator and I am all set. Plus I think my old stator and regulator are "probably" still good.

Thanks for the help

 

Glad you discovered the problem. I've heard of a magnet coming loose - but 5? That would explain the weak charging! Have you put a new rotor on and gotten it buttoned up and tested yet? You should be getting 16-20 Volts AC for each 1000 RPM.

 

All back together. Checked stator before connecting to regulator and 19 volts AC at 1,000 rmp and 50+ at 3,000 rpm. Finished the connections and charging just fine again. Just another odd one to add to our experience.

Great having this forum to bounce things off of.

Thanks

 

That's great news. Give her a hug from us!