Stator prob

38VAC is waaaaaaaaaay too low they all should be around 80VAC up to about 5000 rpm approx.

Once you have the replacement fitted check the voltage coming out of the reg/rec unit to ensure it hasn't been damaged.

Make sure the wiring is all intact first before buying any new parts.

Seem to have read that there may be some kind of a wiring issue where the stator wires enter the casing. Will have a look for it for you.

If one shorts to earth then it will drag down the others and may fry the regulator too. Would advise not to run it until it's been sorted.

also

it is possible to fit a stator from an early mille if your competent a modifying the wiring

see my Pm to you chap but connector behind expansion tank melts and goes high resistance.

Sometime the high resitance takes out the stator or sometimes it melts so bad it shorts to earth between cylinders.

Being optimistic at 38v it's unlikely to have shorted as it normally fails completely on that phase then so you might get lucky and it's just the connector. If you put another stator on with a wiring issue still it won't last very long.

regards stators pre 2004 370w, post 2004 500w. 370w will work but not sure for how long. suck it and see if it's cheap/free.

Bloody hell, another Brown connector that likes to melt. What kind of chocolate do Aprilia use for these exactly? :jack

Spoonz - what years are susceptible to this plug issue - mine is a 2002, so is it worth having a check on mine.

The pre 2004 bikes only have 1 connector like the pic near the regulator the later bikes have 2. It melts very rarely on the earlier model but it has been known.

The 500w stator is the main reason for the problem though. The way the rsv charging system works is to produce 100% stator capacity 100% of the time and dump the excess via the rectifier hence why the heatsink is always very hot.
That means those connectors have all that juice constantly running through them and the moment they develop the slightest resistance through dirt etc then they heat up much like the rectifier and melt.

on a 370w stator you are pumping out less juice so things don't get so hot, hence less problems.
As it happens Aprilia are now producing a 370w stator for the post 04 bikes but they have not made it known generally. It kind of sneaked onto the parts list.

Without going into detail the reason is suspect the pre 04 370w stator won't last in the later bikes is thus.

There are 2 ways to alter stator output. firstly the number of windings on the stator. second the magnetism of the flywheel.
Aprilia (denso) went the magnetism route but also had to alter the winding design to cope with the heat of the extra output.
If you put a pre 2004 stator in then you are putting the winding designed for a much lower magnetism flywheel into a higher temp situation than it was designed for and it's gonna get hot. How long it would last :dunno maybe depend on the sort of ride lengths you do etc.

What about this ??

http://www.electrexworld.co.uk/#8216X0

Electrex one won't last. I know people who have tried and it didn't last long.

You could ask them to rewind yours in thicker wire .

spoonz said:

see my Pm to you chap but connector behind expansion tank melts and goes high resistance.

Sometime the high resitance takes out the stator or sometimes it melts so bad it shorts to earth between cylinders.

Being optimistic at 38v it's unlikely to have shorted as it normally fails completely on that phase then so you might get lucky and it's just the connector. If you put another stator on with a wiring issue still it won't last very long.

regards stators pre 2004 370w, post 2004 500w. 370w will work but not sure for how long. suck it and see if it's cheap/free.

Click to expand...

mine did that too!!
CK