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December 16th, 2005, 08:44 AM   #1
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Stators keep going bad

I have a 2003 FE400E , got it new in Jan 2005 and have had to put in 2 stators so far. Is there a reason why my stator keeps going bad. Is something else causing this problem. I have a weighted fly wheel if that makes a difference. ( 14oz )
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December 16th, 2005, 09:49 AM   #2
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Re: Staters keep going bad

They have been proven to be vibration sensitive, maybe your weighted flywheel is more out of balance than the average OEM flywheel!

It could be the luck of the draw, my original stator lasted 194.5 hours, the 2nd one only 123.5 hours, and the 3rd one only 40.8 hours.

The CDI charge coils R-B failed open in all 3 stators. SEM used 41 gage wire on the R-B and G-B coils. This wire is so fine you can barely see it and makes the design very prone to vibration.

HOWEVER, there is an additional variable to consider, at 299.8 hours, I rebuilt the engine, and replaced the left side crank shaft ball bearing with a roller bearing. This allows the crank to float axially and may add a new vibration mode to the engine?

I have had one of the stators rewound, but am not happy with it. The rewinder replaced the 41 gage wire on the R-B and G-B coils with 38 gage. The bike will not E-start now, and will barely kick start. Instead of putting out 25-30 VRMS at E-start conditions, it only puts out 19.2 VRMS
on R-B, and instead of 3.3 VRMS it only puts out 2.3 VRMS on G-B. He could not get the same number of turns on the coils because of using the larger diameter wire (38 gage).

Regards,

Joe
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December 16th, 2005, 10:19 AM   #3
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Re: Staters keep going bad

I am seriously thinking about carrying a spare stator in my backback, so that I don't get stuck in the middle of the desert, right Chas?
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December 16th, 2005, 10:22 AM   #4
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Re: Stators keep going bad

Hey Chas, I think I have a stock flywheel for that if you want to give it a try. I PM'ed you my phone number.
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December 16th, 2005, 10:42 AM   #5
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Re: Stators keep going bad

Originally Posted by Chasman
I have a 2003 FE400E , got it new in Jan 2005 and have had to put in 2 stators so far. Is there a reason why my stator keeps going bad. Is something else causing this problem. I have a weighted fly wheel if that makes a difference. ( 14oz )
Is it an aftermarket flywheel or was weight added to the original one?
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December 16th, 2005, 10:58 AM   #6
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Re: Stators keep going bad

It's a weighed one. Sent it to Stealy's (?) and had it done. At that time is when my first stater went bad and the bike had maybe 20-30 hrs on it. Only have about 100 on it now.
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December 16th, 2005, 11:08 AM   #7
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Re: Stators keep going bad

Sounds like Joe may have nailed it. You should have a couple of extra flywheels to try as the stator comes with the flywheel .

Are you keeping the stator dry?
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December 16th, 2005, 07:05 PM   #8
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Re: Stators keep going bad

If you do into "The Doc" located in the left hand margin under resources, there is alot of good information on stator care, diagnosis and a cheaper KTM retrofit. I would recommend reading through the whole document as it is very specific to your bike.
Here is the link to the thread containing the KTM stator retrofit.
http://www.husaberg.org/modules.php?nam ... pic&t=2408
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December 17th, 2005, 03:33 PM   #9
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Re: Stators keep going bad

Hi Chasman! You do indeed seem to be having a spot of bad luck. The above mentioned ideas and reference should help you out a lot.
My concerns are with the repetition of your problem, so I'll try to help with some general tips. Since you live in Pheonix; grind a V shaped notch in the bottom of your stator cover so as to create a gap when assembled about the size of a pencil lead. It's hard to keep moisture out and easy to keep it in. The dry desert air will do more to help you than not.
Also be aware of any supporting problems that you may think are non related but could be; a bad battery will put funny heat loads on a stator. So will loose connectors; the arcs they create can wreak havock with solid state regulators. If you continue to have problems give me a call at the shop and I'll try to help walk you through it.
Best of luck, Alan
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December 18th, 2005, 10:28 AM   #10
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Re: Stators keep going bad

If you want a good price on the stator, I recommend ordering it from Munn Racing through KTMTalk.

If you are a registered KT user, Munn gives a 15% discount. Type the part number "58031002050" to find it. It is the same stator as on the 01-03 Bergs and referenced as the 1995 LC4 stator by KTM. With the discount it comes down to $136.95 + shipping. Of course you can call Munn directly.
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