I have a 2006 800 that I had to replace the stator on 1 1/2 years ago, due to it not charging, and the stator was burned. I installed one from RM Stators, and now this one has burned up as well. I just replaced it with another RM Stator, and this time I replaced the voltage regulator as well with one of their Mosfet style regulators. My question is, why are they burning up? I can maybe understand the first time, as it was 12 years old, but this second one only had about 29 hours on it. Maybe it was just a bad one, but I suspect there must be a cause for this.
The one thing that's different is that I installed a Rigid LED 6" light bar on it prior to the first stator burning up. I spliced it into one of the high beam headlight wires. I know that a separate relay would be more proper, but this is a fairly low wattage light; I can't remember but am thinking about 45 watts. I also have aftermarket hand warmers on this. Would the combination of hand warmers and the LED light really overwork the stator to cause it to burn up? I have had the hand warmers on it for about 9 years now. I am considering cutting the wires to the high beam lights to disable them and only use the Rigid LED when I select high beam, as it makes a lot more light than the headlights and probably draws less amps as well, but thought I would seek out opinions before I do that. I should add that the connectors all look very clean with no signs of burning or arcing and they are full of dielectric grease.
Edited by joevh, 12 November 2019 - 12:17 PM.