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Discussion Starter #1
Need some advice from the knowledgeable TROOPERS. Riding home the other night, I shifted into 4th, when my RPM's started fluctuating. I was able to accelerate, but it struggled. I pulled in the clutch and bike stalled. Bike has not started since. Checked valve clearance and cam chain, no problems. When you activate starter, you hear something in left side case, like a chain is broken. Does anybody have any idea? I had the recall done.
 

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Left side noise: Stator or magnets come off the flywheel?

Do you have a V meter? Did you see any charging issues prior to it stopping to run? Battery empty?
 

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Left side noise: Stator or magnets come off the flywheel?

Do you have a V meter? Did you see any charging issues prior to it stopping to run? Battery empty?
Magnets are encapsulated on the bike in question.
 

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Since you had the recall done, I'd look at something having to do with that. Possibly, something came loose having to do with that recall service. Possibly one of the bolts that holds the stator or crank position sensor, which is replaced along with the stator, worked loose.
 

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Oh, this doesn't sound good.

Did they just complete the stator recall?

I'd bring it back, they may have messed something up in the starter system.
 

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Like others have mentioned I bet it's stator/recall related. These engines are bulletproof and I seriously doubt something major went wrong on it's own. Maybe you'll find a socket that the tech left behind. :wink2:
 

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Pull the side cover and take a look, it's way easier then pulling the valve covers. Then....pictures please<img src="http://www.stromtrooper.com/images/smilies/icon_wink.gif" border="0" alt="" title="Wink" class="inlineimg" />
This. Just lay the bike on its side, and you don't even need to drain the oil.
 

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Okay. Here are the pics and problem. It was the CKP Sensor bolts. One was still in the bracket, but barely. The other one was in the case. Neither one appeared to have any loctite on them. The CKP sensor has some rub marks, but I'm hoping its not damaged to bad. I'm guessing these bolts were replaced on the recall, but not sure. Haven's said anything to dealer yet.
 

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Ok, that's good you found the issue, but you lost elec power and I suspect one of those bolts did some damage to the winding's. Those bolts have to come out to replace the Stator, so all this in on the dealer that performed the recall.
I don't like what I see here....could be the angle of the pic, but it looks like fried winding's:
 

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I think that's insulation, not fried windings. It's unlikely any damage was done to the stator itself. It does look like the magnets have been in contact with the core of that sensor though, and bridged the gap between the two poles. Here's a pic of the sensor from one of my old stators showing that gap. You might try taking the tip of a knife or chisel and opening that gap back up. Hopefully no damage was done to the magnets. And you'd be good to go. Or you can let that same dealer replace that assembly again.
 

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I was thinking about this issue, and how the OP found no loctite on either bolt that loosened up. I'm sure I used no loctite on any of the bolts internal to the engine when I replaced the stator, twice, so I checked the manual and indeed no loctite is called for. I'm sure I've never used loctite any other time I've done work inside an engine, so that's not unexpected. Those bolts just were never tightened properly.
 

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First the Crankshaft Position Sensor cannot come in contact with the stator or magnets. It operates on the outer diameter of the rotor. There will be some raised metal squares on the outer diameter of the rotor that allow the sensor to measure from.

The sensor and stator are one part. I would show these pictures to the dealer. Obviously the mechanic that done the recall swap didn't tighten these bolts. I don't think loctite is prescribed for them in the book. If the sensor shows damage, I would ask for a new stator assembly and a new magneto cover gasket. The dealer should be happy to give you those if you are willing to fix this mess for them.
 

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Take it to the dealer and make them fix it. You may have already shot yourself in the foot by opening it up yourself, as they can now claim that it was something that you did and not them...
 

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First the Crankshaft Position Sensor cannot come in contact with the stator or magnets. It operates on the outer diameter of the rotor. There will be some raised metal squares on the outer diameter of the rotor that allow the sensor to measure from.
I was under the impression that those raised metal squares are the magnets. I studied them pretty closely when I've had that section apart. If the magnets themselves are on the other side, then I'd open up that gap on the sensor, button it back up, and hopefully be done with it. Even if those squares are the magnets as I thought, I'd probably do the same. Anything to avoid letting a dealer touch my bike again.
 
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