Hi, Im new to this forum and looking for some help.. im a member of arctichat and snowmobileforum and just looking for some more ideas or insight to my problem , here it is:
After replacing my stator with another new one ( 3rd one in less then 100 miles), i obviously have another problem that's causing my stators to toast. I have went through every piece of wire on the sled, and nothing looks cracked, broken or loose anywhere. My grounds are in good shape and nice and tight as well. There is no trouble codes coming from the ecu, one flash at start only. Im lost at this point? What could be causing this? Voltage regulator? Bad trigger? Flywheel? Any ideas would be greatly appreciated. Thanks

I would say Voltage regulator might be the problem.

What are the symptoms prior to failure? A failing voltage regulator will either burn out lights (lack of voltage control) or may prevent lights and other electricals from working fully. Are the stators testing out "dead" when the give up? What readings do they give?

Yeah if the regulator is disconnected or dead it will allow overvolting and blow out your lights and possibly the ECU. I've also had one (on a Polaris) that was drawing away most of the voltage and made the lights very dim (intermittently but persistently) - replacing the regulator fixed that.

If your electrical is working normally until the stator goes out, I suggest that your motor may be the problem. If the MAG side crank seal is slightly leaking, it will make the stator (and the piston and cylinder) run too hot and could be simply burning it out. If you are putting too much draw on the stator for some reason (could be many many reasons, but it has a maximum wattage and it's harmful to exceed it) that can overheat the stator even if the motor is otherwise fine.

On my 1990 EXT Special, toward the end of last season it developed intermittent electrical cutouts (not to the spark plugs, but all the lights and guages would go dead off and on). I traced and cleaned every connection to no avail. Then one day I got a TEMP light, found that the water pump belt was loose and I had a blown head gasket on the MAG side. After fixing that (leaving the motor in the frame, never disconnecting anything), the electrical worked perfectly again. Forensic evidence suggested that the MAG side head gasket was already leaking prior to the time when I saw the TEMP light, and my electrical problem occurred even when the motor was cold, so that suggests to me that *somehow* (don't ask me how) the leaking MAG side head gasket was causing my stator problems. I imagine that drips of coolant or steam from the cylinder/crankcase ingesting coolant were getting into the stator and fouling it up or causing a short, but really I have no idea.

A slightly melted head gasket can be very very difficult to diagnose because in many cases the sled seems to run great. But if you lose small amounts of coolant every time you ride, yet there is no visible leak, it's probably the head gasket. After replacing it, the motor ran essentially the same but the idle became a lot smoother and less rattly (and the electrical problem was unexpectedly fixed).

So if the stator is either overheating itself (due to too high power draw), or is being overheated by external forces (too hot combustion or poorly circulating coolant), or maybe getting coolant in it, any of those could be the root cause of your problems. That said, I have never had a stator actually quit on me permanently, so I don't have direct experience with this. Hope that helps. I've seen a lot of electrical problem posts over the years but this one seems a bit unusual. Best of luck.

Hi, Im new to this forum and looking for some help.. im a member of arctichat and snowmobileforum and just looking for some more ideas or insight to my problem , here it is:
After replacing my stator with another new one ( 3rd one in less then 100 miles), i obviously have another problem that's causing my stators to toast. I have went through every piece of wire on the sled, and nothing looks cracked, broken or loose anywhere. My grounds are in good shape and nice and tight as well. There is no trouble codes coming from the ecu, one flash at start only. Im lost at this point? What could be causing this? Voltage regulator? Bad trigger? Flywheel? Any ideas would be greatly appreciated. Thanks

Don't overlook the condition of the flywheel as well..