Forum

[Barry_Q]

When my Ignition wire failed. It was around the headstock. I simply patched in a piece of wire. When it comes to modifying a loom. The ends are left intact, but a new length of wire gets inserted along the length (so the crimped ends remain intact. Another advantage is that the correct coloured wires are seen at the ends.

[Barry_Q]

Just a quick update folks. I've now stripped back the loom as far as the horn wires. I didn't find any broken wires (I did uncover where the ignition had previously broken). However. I removed the insulation from set of spliced wires (Where multiple wires are soldered together). The joint looked a bit dry. It's quite possible I've got a dry joint problem. The investigation continues.....

[Barry_Q]

Mystery solved folks. Knackered alternator. I couldn't find a break in the wire. Nor were there any dry joints. Frustrated. I pulled the connector from the AC regulator and connected a spare battery. The headlight lit up! I then disconnected the Amber and Yellow AC light wires from the alternator and reconnected the battery. The headlight lit up again! I'll connect the headlight direct to the battery for the moment, so I can keep riding. But a new stator is winging its way here! I'll replace it next weekend.

[Tim NZ]

The most common cause of stator 'failure' is often only a lead-out wire breaking...


Open circuit? Any significant difference in colouration of the stator windings?


(Burnt/overheated)

[Barry_Q]

I did check the AC side of the stator. It's open circuit. The DC on the bike works fine (Battery charges). I won't know the condition of the stator until I remove the primary side cover. I won't be doing that until I replace the stator at the weekend.

[devon john]

i had a fire in the loom on the bullet , managed to pull the battery before it really got hold ,,

so this prompted me to rewire ,,,

pulled all the loom out and started again ,,, there was 32 wires going to the head stock ,, so o moved the ignition and light switch to the toolbox.

theres now 7 wires to the head stock , i used finwall 7 core trailer cable,

i also fitted modern blade fuses and spilt the system to 5 fuses ,

a little time but i think much safer ,

john

[Barry_Q]

Just a quick update folks. I've removed the clutch cover and I found a right mess. Metal everywhere! Further investigation revealed that a magnet from the rotor decided to escape! I'm amazed that the DC circuit was still working (thus charging the battery) abet at a lower rate. Just one question. Does the nut that holds on the rotor, unscrew in a clockwise or anti-clockwise direction?

[Barry_Q]

Don't panic folks. I've got the rotor off (It's anti-clockwise). There was one more piece of damage. The woodruff key had sheared (Not really surprising). Again, I'm amazed that the Lightning kept going! No wonder India had the Bullet. It can take an enormous amount of punishment and still keep going! I'm off to buy some bits. At our hosts of course.

[Barry_Q]

All's well that ends well. Lizzy the Lightning is back to normal (what ever counts as normal). Happy days!

[Barry_Q]

Just as an add-endum. A spot of good news. I've been out for a ride. My tacho is working again (It hasn't worked for over a year). My ammeter now shows a charge (It's never done that before). I suspect that these 'bonuses' are from when I pulled the wiring loom apart and squirted switch cleaner everywhere. Result!