'95 SL750 electrical question....

[Cloudten]

Hello again!

Ski ran great all summer with 50+ hours on it this year! And then, I smoked the wiring from the Stator back to the electrical box. I was wondering, do I need to replace the stator or can I just run new wiring? I can't seem to find the manuals, so I know how to tear apart the stator and look at a schematic? Am I missing them?

Thanks in advance!

-Justin

[beerdart]

Check the main ground to the bedplate.

[K447]

Was the plastic insulating cover missing from the battery, out of place, or worn through?

One way to burn up the Black stator wire is to have the battery positive post short to the metal shell of the electrical box.

You may be able to just replace the burned wire(s), depending on where the damage stops, and how much got damaged.

You may need to remove the flywheel, and then the stator, to get to the 'good' section of the wire. There have been several threads discussing Fuji engine flywheel removal.

Check the black wires inside the electrical box, some of them may also have been damaged.

[xlint89]

If the stator wires ohm test good, you can just replace the wiring.

BUT, I'd have a back up stator on hand anyways.


50 hrs of riding in Cleveland, and not 1 PM???? I see how it is....

[Cloudten]

Before this whole thing started, I'd be riding along and the ski would quit, the MFD would blank out, and it wouldn't turn over at all. A total electrical failure. I'd move the wiring around and it worked again for a few days. I tightened down the battery terminals. They were a bit loose. Worked again for a few days, until this...

It burnt the insulation completely off the black wire and partially from the yellow wire. I suspect they chaffed together at some point. After I separated the wiring from each other, it starts right up. I think the harness is the only problem.

I can build a new harness. I just need to know how/if it connects to the stator. I'm assuming I need to take it apart and the wires are soldered to it? I'll search for stator threads.



It's hard to PM anyone when my ski works! I'm down at edge water like three or four times a week. I look for other Polaris riders (there's a bunch), but none from this board. I'm down to ride, if I can get this piece fixed.

Thanks for getting back at me so quickly, again.

[K447]

Be sure to ohm check the stator coils, and if you have the stator out, visually check the coils for any signs of damage.

Also check that your battery is actually charging after you get it fixed. Charging voltage should be 13.5-14.5 volts with the engine running.

[Cloudten]

Will do.

I can't get the stator housing apart. Need to bring tools home from work. Are the wires hard wired to this thing? From looking at pictures, I can't tell. Looks like a few are screwed to it.

I cut the harness out and there's barely a few pieces of insulation left on the ground wire all the way down. I'm just going to build a whole new harness.

[starflight]

They appear to be hard wired/soldered and then glued over. I couldn't really see where the black wire ties in. I wonder if you just bonded it to the stator plate, would that be good enough?

[Cloudten]

Thank you for the pics! I'm might actually try to ground it somewhere else. If the yellow wire isn't toasted at the stator, I should be golden! I just built a new harness as well.

[xlint89]

Ohm test the stator before you go putting new wires on it.

I have a spare stator if you need one ASAP.

They are soldered on the part.

I have one that was repaired from the same issue you had.

The guy just clipped the wires close to the stator and soldered new wire to it. Then heat shrink. As long as it tests well.