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1999 R6 - "Project Dreamweaver"


feliks
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Hey guys, been a while... but I've been out enjoying the new ride and the awesome weather here we're finally getting. So far so good with issues, some small things here and there... but just recently I started having charging issues.

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Long story short, battery died while riding, bump starting wasn't working, had to disconnect the headlights in order for the bike to start with a bump, got it home, inspected wiring and found this:

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So I cleaned it up, added some new lengths of wire with dual walled waterproof insulated heat shrink tubing and heat shrink connectors. The RR appeared ok, but I guess it could be shorted out on the inside, wondering if I should risk trying this one or get a new one.

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Then I tested the stator coil and every single lead had continuity to ground, which, is not good! I also was not getting the correct readings between leads...but that test was unnecessary since it was already grounding out. So I took out the stator and found it all burnt up! I'm assuming it burnt up because of the regulator connections shorting out, would that be a correct assumption? And if so... after cleaning up the wiring for the regulator (which is now proper!), will I have any issues blowing this new stator up by plugging it into the old regulator/rectifier or should I get a new one of those as well just in case?

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So my poor bike is parked until Tuesday :(, which is the earliest I can pick up my new stator!

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Oh bad luck Feliks, always a sod when it lets you down far from home. Your right I think that the Reg has cooked the stator, it would be overcharging so cooking the various connectors, should be ok once you get a new stator on it but remember to check the voltage before you take it out. for a run.

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Bike has left me stranded 3 times so far, first time it was a fuse, second time a bolt fell out of the clutch cover and started shooting oil everywhere, and the 3rd time the charging system fucked up... all within a month of owning the bike.... lol Ah well, a run of bad luck is sure to be followed by a run of good luck! :D

I'm not going to fry the new stator using my old RR, am I? I can only assume it was because the wires themselves on the outside shorted out (you can see how badly frayed and exposed they were) - so I'm hoping I don't fuck the stator up when I plug it and turn the bike on with this RR still.

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Very pretty mate, should think you will be ok with the new stator as long as the short circuit has been sorted properly, best to check the voltage output before you go out tho.

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Oh yes, will be checking everything before I pull it out of the garage! Don't want to be stranded somewhere. I must say though, every time I was left stranded, I ended up being able to fix the problem temporarily and ride the bike home so I can't say anything bad about the old girl. :D

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When your at NCK salvage try and get the right plug for the regulator and get rid of the individual connections.

Most likely the regulator went first and full fielded the stator causeing the wires to get hot and melted the plug,have you had bulbs blow recently? is the battery low on fluid?

if you can afford it grab a RR while your there you will need one sooner or later and if you drive all the way 2x it's going to cost almost that in gas as to buy one now. And if you get home and find you need it then your down for more time.

I take it you allready checked to see if the one from the fz would fit?

Keep the old one and have it rewound or do it yourself.

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The wife is actually going to take the trip out there for me (I have to be here in the morning to work and she knows how much this is killing me to not ride right now, she's awesome. lol) so I'll ask her to get a RR while she's there, might as well be safe, don't want to fry the new stator. Like I said the RR "looks" fine but since you can't test it I'd rather not risk it.

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I got a reg/rec from China and was very cheap. Only downside is it takes a little while to come.

Get one anyway as a spare

Sent from my RM-914_eu_euro1_280 using Tapatalk

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Installed the new stator, and although the bike is holding a charge at 12.5v even after riding for half an hour... it won't go above 13v while running even at 5000 rpm. So....RR must be done as well. I bit the bullet and ordered one from yamaha... $100 used from the bike wreckers or $170 new from yamaha (I know that's a lot but there's no way I can wait for one to come from China... I'll just work a few extra hours this weekend to make up for it!).

At least I got out for a little ride today! :D

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Check all your grounds and load test the battey with a carbon pile or check each cell with a hydometer a 5er will get you a battery cell tester from princess auto

If the rr was bad it would go over charge or no charge normaly. I would suspect that the stator is week/bad cell in the battery or poor ground.

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Installed the new stator, and although the bike is holding a charge at 12.5v even after riding for half an hour... it won't go above 13v while running even at 5000 rpm. So....RR must be done as well. I bit the bullet and ordered one from yamaha... $100 used from the bike wreckers or $170 new from yamaha (I know that's a lot but there's no way I can wait for one to come from China... I'll just work a few extra hours this weekend to make up for it!).

At least I got out for a little ride today! :D

$170 for a few hours work at the weekend what are you Felix some sort of male escort ? :babyha:

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Check all your grounds and load test the battey with a carbon pile or check each cell with a hydometer a 5er will get you a battery cell tester from princess auto

If the rr was bad it would go over charge or no charge normaly. I would suspect that the stator is week/bad cell in the battery or poor ground.

Flip the battery was toast and is the sealed type so you can't hydrotest it... constant charging/draining killed it I think, plus who knows what kind of shape it was in before I got the bike. Picked up a new AGM one from GNB Battery here in Hamilton and installed my new regulator, now reading a fantastic 13.6v while the bike is on, instead of 12.1v which I was getting. Woooo hoo! All fixed up. :D I've got the dreaded 2nd gear slip now though under hard acceleration... would you suggest finding an 03 tranny to swap with or just replacing the worn gears in mine? It'll be my new winter project this year.

$170 for a few hours work at the weekend what are you Felix some sort of male escort ? :babyha:

A few as in like 5 or 6 extra hours... lol

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If by slip you mean it's poping outa gear, I would pull the gears out drop them off at niagra race craft ( they are about the closest place for you )and have them under cut and replace the shift fork. Cheaper and better fix.

Did you test the chargin with the new battery before changing the RR?

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It's not popping out of gear, I would describe it as rear tire slip, that's what it "feels" like...but it's not, and it ONLY does it in 2nd gear, no other gears... from what I read online the 2nd gear in 1999-2002 R6's is fucked...and goes out very soon in their life... so plan is to crack it open and fix that up this winter! Hopefully that goes well...

Yes I did... the regulator was fried though, wasn't putting out the needed voltage, was still only at 12v when running.

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Well if it's not poping out of gear then it's not the gear it's self,I would say you have early stage of clutch wear.

The gears cant slip/spin on the shaft without breaking off every noch and then they would spin and do nothing at all. Have a look at one of you extra tranny's and you will see what I mean It's imposible for the gear to slip

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It doesn't pop out of gear, just slips when you hammer on it in 2nd. I don't doubt you at all I just don't know how that would be the clutch if it only does it in one gear, but you would know more than me about this stuff!

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So this seems to be the issue... the 2nd gear has 3 gear dogs on it that engage it to the tranny whereas the 03 and up tranny's have 5 dogs on them... so these get rounded off in 2nd gear for some reason and almost every 99-02 R6 has this. :( I can either ride as is, or fix it. I'm gonna fix it come winter time, woo project time! :D

they are actually called "dogs" by yamaha.
the R6 used to suffer from the 2nd gear slip. they said in 03, they put 5 "dogs" on each gear to eliminate the problem. the 99-02 used 3 dogs on each gear.
the dogs are the tabs that stick out on each gear that locks it into the next gear.
if they round off too much, they will allow the gear to momentarily unlock from the rest of the gears. and that's the "slip" you are feeling.
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