1990 Kawasaki Bayou 300 Stator Issues

whitmod · 10-06-2009

I recently purchased a used 1990 Kawasaki Bayou 300. Before I purchased the 4-wheeler, I knew there was some type of electrical problem with it, but wasn't sure what it was. I made the purchase and decided to try and fix it myself.

Here's the problem:
The three yellow wires coming from the stator/alternator that connect to the rectifier become hot enough to discolor the wiring. The rectifier also seems to be very warm.

What I've done:
With an ohm meter, I've checked the three yellow wires coming from the stator/alternator. None of them show continuity to ground (frame) and there is approx 0.8 ohm resistance between each of the wires.

With the recitifer disconnected from the wiring harness, the engine runs and the wires do NOT get hot.

The fuse coming from the positive post of battery is okay while the yellow stator wires become hot. The fuse stays intact (not blown) while engine runs.

The battery passes a load and voltage check (Autozone). Battery voltage while engine off is approx 12.0v and with engine running is approx 13.5v.

All other systems on the 4-wheeler seem okay i.e., the single work light works on low/high beam (not extremely bright or dim) and tailights are ok. The neutral and reverse lights work in same fashion.

I'm at a loss and need help as what to do next. BTW, the engine will not run with the battery disconnected. Is this correct?

Please help!!!!!

whitmod · 10-07-2009

Anybody have any thoughts on this problem? I'd like to get this thing going and ride before weather turns bad!!!!!!!!!!!!!

86klf300guy · 10-07-2009

well when wires get hot that means there is alot of resistance on that circuit.id check the connections to make sure they are tight at the reg/rec
and no corrosion or crud in that connector.a lose or dirty connection can cause high resistance and make wires hot.

everything you checked sounds good it not over chargeing etc.but also might want to through this in to the mix.make sure there are no extra loads on the system like a winch high powered lights etc.for the extra load may have something to do with the wires gettin hot.a bad battery connection and or battery can cause this hot wire issue also.the battery at rest should be over 12v and charge should be 13.5-14.5which yours is at 13.5 so that cool but that battery may have a issue.

as for the battery diconnected no it will not run.my bayous power wire got pulled out when the battery holder let go and the bike died right there on the spot and caused a little fire under my seat lol.-corey-

whitmod · 10-10-2009

corey...thanks for the reply.

i'm suspicious of battery as well as the check at Autozone was not thorough, IMO. i can switch battery out with a friend's bike as a quick check.

the 4-wheeler does not have a winch, and there are no accessories.

the three yellow stator wires had a factory connector (white, 3-pin) when i bought it, and the connector was slightly melted. i originally thought it had corroded or got water in it causing this condition. i went to parts store and bought automotive grade male/female wire connectors and crimped them on all the wires. i thought this type of fix would be ok. do you think these are not acceptable?

can you explain why some bikes can run without the battery and others (mine and yours) don't? so, the pull start back-up really only works if battery is in system, but not good enough to run the starter? the alternator/stator will not supply power to igniter etc. if battery is removed?

sorry, confused on this...thanks for your help!

86klf300guy · 10-11-2009

as for the connectors if you use the plastic coated ones that cover the male and female blades and have a shrink style tubeing to cover the wire and seal it up i see no problems with that.

as for the battery diconnected and will not run the chargeing system only puts out like 2.0v not 12v.and the coil needs a 12 v supply to fire.

on my bayou i do not have a pull cord for back up mine is all electric ,so if my battery goes im done dead in the water

but note this the reg and rec will always be warm or hot to touch while running.just make sure there is no mud on the componet keep it clean and make sure there no obstructions blockin the air flow that helps keep it cool while rideing.

also may want to clean all grounds at the frame and engine for a bad or dirty ground can cause them wires to heat up.-corey-

10-06-2009	#1 (permalink)
whitmod Newbie Join Date: Oct 2009 Posts: 3	1990 Kawasaki Bayou 300 Stator Issues I recently purchased a used 1990 Kawasaki Bayou 300. Before I purchased the 4-wheeler, I knew there was some type of electrical problem with it, but wasn't sure what it was. I made the purchase and decided to try and fix it myself. Here's the problem: The three yellow wires coming from the stator/alternator that connect to the rectifier become hot enough to discolor the wiring. The rectifier also seems to be very warm. What I've done: With an ohm meter, I've checked the three yellow wires coming from the stator/alternator. None of them show continuity to ground (frame) and there is approx 0.8 ohm resistance between each of the wires. With the recitifer disconnected from the wiring harness, the engine runs and the wires do NOT get hot. The fuse coming from the positive post of battery is okay while the yellow stator wires become hot. The fuse stays intact (not blown) while engine runs. The battery passes a load and voltage check (Autozone). Battery voltage while engine off is approx 12.0v and with engine running is approx 13.5v. All other systems on the 4-wheeler seem okay i.e., the single work light works on low/high beam (not extremely bright or dim) and tailights are ok. The neutral and reverse lights work in same fashion. I'm at a loss and need help as what to do next. BTW, the engine will not run with the battery disconnected. Is this correct? Please help!!!!!

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Kawasaki can make you sick.	Uncle Bob	Off Topic	24	01-15-2009 03:00 PM
1995 kawasaki Bayou 400 4x4 no fire	agravation	The Mechanics Corner	6	08-07-2008 10:59 PM
1990 Kawasaki Bayou 4x4 engine trouble?	snakes80	Kawasaki ATV and Mule	0	08-23-2007 10:52 PM
need bayou 300 rear diff help	ty95daniel	Kawasaki ATV and Mule	0	07-05-2006 10:10 AM

10-07-2009	#2 (permalink)
whitmod Newbie Join Date: Oct 2009 Posts: 3	Anybody have any thoughts on this problem? I'd like to get this thing going and ride before weather turns bad!!!!!!!!!!!!!

10-07-2009	#3 (permalink)
86klf300guy Way Too Much Free Time BTK Expert Join Date: Feb 2008 Location: some where in ohio Posts: 1,203	well when wires get hot that means there is alot of resistance on that circuit.id check the connections to make sure they are tight at the reg/rec and no corrosion or crud in that connector.a lose or dirty connection can cause high resistance and make wires hot. everything you checked sounds good it not over chargeing etc.but also might want to through this in to the mix.make sure there are no extra loads on the system like a winch high powered lights etc.for the extra load may have something to do with the wires gettin hot.a bad battery connection and or battery can cause this hot wire issue also.the battery at rest should be over 12v and charge should be 13.5-14.5which yours is at 13.5 so that cool but that battery may have a issue. as for the battery diconnected no it will not run.my bayous power wire got pulled out when the battery holder let go and the bike died right there on the spot and caused a little fire under my seat lol.-corey-

10-10-2009	#4 (permalink)
whitmod Newbie Join Date: Oct 2009 Posts: 3	corey...thanks for the reply. i'm suspicious of battery as well as the check at Autozone was not thorough, IMO. i can switch battery out with a friend's bike as a quick check. the 4-wheeler does not have a winch, and there are no accessories. the three yellow stator wires had a factory connector (white, 3-pin) when i bought it, and the connector was slightly melted. i originally thought it had corroded or got water in it causing this condition. i went to parts store and bought automotive grade male/female wire connectors and crimped them on all the wires. i thought this type of fix would be ok. do you think these are not acceptable? can you explain why some bikes can run without the battery and others (mine and yours) don't? so, the pull start back-up really only works if battery is in system, but not good enough to run the starter? the alternator/stator will not supply power to igniter etc. if battery is removed? sorry, confused on this...thanks for your help!

10-11-2009	#5 (permalink)
86klf300guy Way Too Much Free Time BTK Expert Join Date: Feb 2008 Location: some where in ohio Posts: 1,203	as for the connectors if you use the plastic coated ones that cover the male and female blades and have a shrink style tubeing to cover the wire and seal it up i see no problems with that. as for the battery diconnected and will not run the chargeing system only puts out like 2.0v not 12v.and the coil needs a 12 v supply to fire. on my bayou i do not have a pull cord for back up mine is all electric ,so if my battery goes im done dead in the water but note this the reg and rec will always be warm or hot to touch while running.just make sure there is no mud on the componet keep it clean and make sure there no obstructions blockin the air flow that helps keep it cool while rideing. also may want to clean all grounds at the frame and engine for a bad or dirty ground can cause them wires to heat up.-corey-

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)