2003 mxz800 dim lights, gauge resetting, started to misfire/bog

catguy

New member
Was riding this weekend with a bud that has a freshly rebuilt machine, transferred tunnels, rebuilt motor and the works over summer. His recoil gave up and we kept riding, he'd use a strap around the clutch to start it for the rest of the day. Later in the day he found that at idle his lights would nearly shut off, wayyy dimmer than at a normal idle, also the gauge didn't have enough power to stay powered up, it'd keep reseting at idle. He was able to pick up a new recoil, we replaced it the next morning and found that the old one was partially melted. (I'm thinking the knot broke and dogs stayed engaged or something like that) At a cold start, the lights would be brighter, once it ran awhile it would start dimming more and more. Finally came to a point where the motor seemed to bog and he stopped riding for the day, got a ride home with a local guy.

I don't know much about doo's, pretty sure voltage regulators are a common item to go bad on certain chassis' doos. But I'm thinking that the stator was heat damaged by the recoil staying engaged. Whats your take? He doesn't run any extra accesories that take power, and shut off the hand/thumb warmers to keep more power available for the lights. He said that at times they'd flicker too. Other than a visual inspection can stator be "tested" for heat damage?
 

jimfsr

New member
The recoil melting is a pretty common event on the 800, and some 600's too. Have replaced quite a few on the '03s. I would say the stator is on its way out, the hotter thay get the worse the work. Get a new one or re-wind the old and the problems should be fixed.
 
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