RD250 Charging Issue

[BlueR32]

I've been driving myself nuts the last few days trying to troubleshoot why my generator won't charge the battery when motor is running. I had a separate post about brush re-assembly which I sorted out (thanks m in sc!). I am running a Rick's combo regulator/rectifier that I got from Economy Cycle and I am assuming it is not defective.
So starting with the generator, I checked the resistance between the rotor slip rings and I am getting 4.5 ohms (within tolerance). Then I check the resistance between each of the white wires from the stator and I am getting 1.0 ohms with all combinations of wire pairs. The manual states 0.30 - 0.35 ohms. Looks like my stator is toast but I'd like to hear confirmation from the experts before I proceed.
Many thanks!

[m in sc]

stator should have continuity each way but 0 to the casing or ground. i doubt thats it.

[BlueR32]

This is what my multimeter looks like with bike running. Same behavior if I pull the red lead off the battery so I assume this means nothing coming back from generator?
https://youtube.com/shorts/n8MDySbStxc

I found this post which prompted me to pull out the brushes for another look:
https://www.2strokeworld.net/forum/index.php?topic=5425.msg45925#msg45925

You can see that the brush faces are angled so according to the above post they might be getting stuck i the holders. Thoughts?

[m in sc]

vid didn't work.

you should eb able to see the neutral light get brighter if you rev it. it wont charge at idle just fyi.

it might be the brushes. ive seen ones that bad work, but if you plan on keeping the charge system, new brushes would be a good idea.

btw, its an alternator, not a generator.

[BlueR32]

Try this vid I made it Public:
https://www.youtube.com/shorts/n8MDySbStxc

Multimeter reads the same if I rev it. Neutral light doe not get any brighter with revs.

[m in sc]

yup.

def not charging.

[m in sc]

worst case, if you need a stator i probably have 5 or 10 of them. lol. you plan on going to deals gap meet next week?

[AAAltered]

Didn't you also have a challenge with the phenolic washers?  Perhaps you have a ground one one of the terminals?

[BlueR32]

Didn't you also have a challenge with the phenolic washers?  Perhaps you have a ground one one of the terminals?

Yes that was me. I could try joining the green and black terminals that go on the phenolic washer directly to test your idea. Thanks!

[BlueR32]

worst case, if you need a stator i probably have 5 or 10 of them. lol. you plan on going to deals gap meet next week?

Regrettably I won't be at the Gap next week, but it's good to know you have a few! I'll ping you directly about that. Thanks!

[grcamna3]

Is there a process on the best way to first remove the brushes,then clean the slip rings so it removes the build-up of carbon that come off the brushes when they wear, w/o removing the alternator assembly ?

[m in sc]

remove the whole alternator housing. zip the point bolt off and point cam, easier to clean. you can leave the rotor ont he crank. use some contact cleaner and gently scrub the rings, i use a red scotchbrite, lightly. if you dont have that, wd 40 works to clean, but dry off. rubbing alcohol will work in a pinch, fit new brushes.  0.02

[grcamna3]

remove the whole alternator housing. zip the point bolt off and point cam, easier to clean. you can leave the rotor ont he crank. use some contact cleaner and gently scrub the rings, i use a red scotchbrite, lightly. if you dont have that, wd 40 works to clean, but dry off. rubbing alcohol will work in a pinch, fit new brushes.  0.02

I remember a person in the past saying 'remove the brushes and use a pencil eraser',but I don't think that will be a good cleaning?

[BlueR32]

My brushes are both 10mm. Min length is 6mm. Is it an option to try to file the ends off square?

[AAAltered]

I have filed them before when they got cocked in the holder.  Be very gentile, that carbon is pretty soft but yes you can file square.