Replaced my stator cover on my 95 zx6e and discovered the wires had been cut. so now I have 3 black wires from the stator and 3 yellow wires from the harness. anyone know what I need to do to get it wired back together properly? trying to avoid buying the manual and I know that's going to be the first comment,

Usually there are three wires of the same colour, they are the stator wires.
When the engine spins the stator this produces three phase energy.
This is then rectified to produce DC voltage and used to charge the battery, if fitted and run any lights, horn etc.

CDI FRIED

Originaly the 3black wires would have been yellow sounds like its been rewired, you can connect any one to any yellow as this is a 3 faze alternator and they all throw ou the same power, before you do so,(with the ignition key removed) use a multimeter set to ohms put red lead to one wire record the reading when you touch the black wire to one of the other two wires, next move the black and record reading to the other of the two wires, this will determin that you have continuity around the three circuits

Locate the wire harness coming out of the stator on the left crank case cover of the motor and follow it to the plug with three yellow wires. This is the stator plug. You should have continuity between any combination of the three yellow wires, but no continuity between any of the yellow wires and ground. If the stator yellow wires are grounding you will have to replace the stator. To replace the stator remove the left crank case cover and unbolt the stator from the inside of the cover. Do not forget to purchase a new left cover gasket with the new stator or you will just delay your riding.

Locate the wire harness coming out of the back of the motor and follow it to the plug with three yellow wires. This is the stator plug. You should have continuity between any combination of the three yellow wires, but no continuity between any of the yellow wires and ground. If the stator yellow wires are grounding you will have to replace the stator. To replace the stator you have to remove the motor from the frame or at least unbolt the motor and rotate it enough to remove the rear cover and unbolt the stator.

TRIAL AND ERROR. THE PROCESS IS TO MAKETHECABLE IBN A STRAIGHT A LINE AS POSSIBLO........GET YER TEA MADE AN YER SPANNERS OUT

Locate the plug coming out of the back of the motor (under the seat) with three yellow wires. This is the stator plug . You should have continuity between all three yellow wires and no continuity between any of the yellow wires and ground. If a yellow wire grounds or there is no continuity between two of the wires , you have a bad stator. You will have to take the motor out of the back of the bike, remove the rear cover, and replace the stator. It is a 3 to 4 hour job.

To check the stator, you should have continuity between all three yellow wires and no continuity between any yellow wires and ground. If the stator tests good you probably need the regulator/rectifier.

It's much more likely that its the stator although they do do the odd regulator as well.
Start at the stator first as it is easier to test.
Disconect the stator wires-sometimes behind the front sprocket cover-sometimes further up the wiring loom.
Using a multimeter check for resistance between the yellow wires (3x) comming from the stator cover. Check that none of these wires has conunuity(connection) to earth.
If any/all do you have a burnt out stator- remove the stator cover & inspect- the windings will look burnt & smell bad also.

If the stator tests fine then the reg is most likely the problem.

Hope this helps-
Regards Andrew

Yes, you can have it aluminium welded, do it your self with Lumiweld or patch it up with an epoxy resin.
Ride Safe
Bike-Doc

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