Shutdown on highway

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my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Shutdown on highway

Postby my79650 » Fri Jul 05, 2013 11:12 pm

Finally after i replaced my rotor, fixed the harness for the stator and replaced the r/r with a new one today; i was out for a night drive to test the electrical system. I got about 15km from home and was doing 110kn/70mph on the hiway and all of a sudden i lost all my lights(headlamp, dash, driving lights)and the engine quit. Pulled over and i turned off the key and checked the kill switch then checked everything. The only lights i got was the oil and neutral and they were very dim. The rear tail light worked on the park side of the key switch. Any ideas on this? Nothing worse than being towed after midnight.

usbear
Posts: 361
Joined: Sun Mar 10, 2013 9:55 pm

Re: Shutdown on highway

Postby usbear » Sat Jul 06, 2013 9:44 am

I put a banshee rotor and stator on a xs 650 last year and it did the same thing in about 15 miles. The wires coming out of the stator touched the rotor and wore through the insulation and shorted everything out. The wires had to be clamped away from the rotor and were silicone'd in place to insulate them and prevent chafing.

If the wires got pinched by a case or wore from the chain , same results.
Might check for pinched or worn wires and a short through the insulation.

my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Re: Shutdown on highway

Postby my79650 » Sat Jul 06, 2013 1:26 pm

Pinched wire from the stator, my fault for not making sure it was routed properly. Melted the black wire up to the connector and it also ruined two yellows. I have another stator from the parts bike, it has a short brush. The 3 screws for the stator came loose but the 2 for the brushes won't turn. I can't get in ther with my manual impactor and i don't want to drill them out and rethread. Only other thing is to splice that good harness onto the one with the burnt wires and solder everything outside the case where it goes from the crankcase cover to the stator mount. There's a 3 or 4" space ther that the harness doesn't touch anything. Or i can just go to the salvage yard and get another complete assembly to drop in. Volker_P or tidd650: i tried several times today to load photos and it did allow me to load 1 pic but if i do 2 it says the server error.
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my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Re: Shutdown on highway

Postby my79650 » Sat Jul 06, 2013 1:33 pm

Apache server at www.hondacb650.com port 80 was the screen message after i tried to add another picture.

my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Re: Shutdown on highway

Postby my79650 » Sat Jul 06, 2013 4:32 pm

I did the splice job; soldered and heat tubing to seal it up. Maybe my tester is going bad, i set it to 200 ohms, my lowest setting and checked the 3 yellows. They leveled between 1.5 or 1.6. I hope its the tester cause my other stator tested nearly the same way before i took that harness. But when i set it to volts and check my battery it last said 12.9v...maybe the ohm side of the unit is too sensitive.

my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Re: Shutdown on highway

Postby my79650 » Sat Jul 06, 2013 8:22 pm

Back in from a short drive, same mileage as last nite, 13kms@110km/hr. since the screws for the brushes wouldn't turn i spliced the good harness onto the stator harness that fried. worked good and kept everything charged. Check the battery volts in the morning; time for beer!

my79650
Posts: 643
Joined: Tue Apr 06, 2010 11:37 am
Location: Gagetown, New Brunswick Canada

Re: Shutdown on highway

Postby my79650 » Sun Jul 07, 2013 4:11 pm

Was 12.32v before i went for a drive. stopped after 30kms and checked it again and the reading was a little higher. didn't bother checking it again as i was in a town with a lot of stop and go streets. The signals and brake lights worked properly. And the neutral light got brighter when i stopped it and revved it up. Long story short, charging system is performing properly. Now to replace the valve cover gasket as i had oil all over the #4 carb and sifde cover.


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