How to load test a stator on the bench! Best method ever for "dyno" testing alternator windings!
Channel: How 2 Wrench
Date: 15/10/2016

I’m been using this method of alternator stator winding load testing for years. I learned about it through factory Suzuki MTM training 20 years ago. 

What you are doing is “load testing” the windings by “pushing” around 5 -7 amps through the winding to complete the low beam of a standard headlight. 
Question 1:
Why is this better than the old fashioned way of continuity testing? 
Answer:
A borderline failing stator will sometimes not fail without a load. This load provides the instant heating of the wire insulation to test it's integrity instantly. 
Question 2:
Why wouldn’t I just test on a running bike?
Answer:
1. Sometimes we are in a position where this is a super time saver as the bike may be apart when we get it. Think: installing, new gasket, adding oil, warming up engine and testing to find out its bad under load. 
2. This test does not require the stator to be removed from the engine either.
3. A borderline failing insulation will show its ugly face right away with this test saving time and money.
4. This test takes the guess work out and provides confidence in replacing the correct part.

Click the links to playlists: (entire list link is the last one) 

Harley EVO: https://www.youtube.com/playlist?list=PLAtBOuPaEyt95-wqtiOFk3tzUW2VARbHI
Harley Twin Cam: https://www.youtube.com/playlist?list=PLAtBOuPaEyt_7aGpzL9DxDVZy_fofjo1G 
4-Stroke Engines: https://www.youtube.com/playlist?list=PLAtBOuPaEyt-iDjXbKCN_b7_oRwTW2uAY 
2-Stroke Engines: https://www.youtube.com/playlist?list=PLAtBOuPaEyt_pO6zS6U7Rpjk-uCEYZZ8O 
"Every Mechanic Should Know This Training": https://www.youtube.com/playlist?list=PLAtBOuPaEyt_uMyVlK1tsBVnSYW1Q0vCK 
Transmission: https://www.youtube.com/playlist?list=PLAtBOuPaEyt_VMoD82dhOk5XpIXMUASOU 
Wheels, tires, brakes: https://www.youtube.com/playlist?list=PLAtBOuPaEyt8u703ZrvtvAUUuKIv6p2Ck 
Electrical: https://www.youtube.com/playlist?list=PLAtBOuPaEyt_y8Ua2r49WYf0nLzYXT9eA 
Fuel, air, intake: https://www.youtube.com/playlist?list=PLAtBOuPaEyt-ZMVRlpvWmVFLL10P16vWf 
Suspension: https://www.youtube.com/playlist?list=PLAtBOuPaEyt-SLKUotAxQE1llsyQ_T0x2 

All playlists by type: 
https://www.youtube.com/user/conleybuilt/playlists 

You will see that many of the tips and procedures used are universal for skill sets "every mechanic should know" and that the biggest value to my videos is the teaching of these skills that are not found in a service manual. 
I often get asked this question:
Q: How does one learn these skill sets "every mechanic should know" if they are not found in a manual? 
A: NUMBER 1.....GET DIRTY and start wrenching. 
-Ask questions
-Find a seasoned craftsman to mentor under
-Tech schools can significantly speed this time up
-Research, read, watch YouTube videos
Tip: You will never learn it all from one source or in a short time period. No matter what craft you are trying to master, YOU must be dedicated and put the time in. THERE IS NO BETTER WAY TO LEARN THAN DOING! I will say it again, you must actually do the work to master it. You cannot just watch or read about it and master anything.
You want to be a master bike builder, mechanic, welder, nurse, carpenter or you fill in the blank? 
-Don't take for granted opportunities to learn deeper
-Be humble and seek advice
-Be intentional with your learning plan
-Don't blame a school, job or your parents for not giving you ever answer, go get it!

I teach a motorcycle/powersports technician program at Western Iowa Tech Community College in Sioux City, Iowa. These videos are used for review of labs for students and creating a deeper understanding of the lesson/skill set. As there is often more than one way of doing something, may you enjoy this free information as much as our students do in person. PLEASE HIRE OUR GRADUATES! 

If you would like more info on the program feel free to contact me @ 712-274-8733 ext 1204 or email shane.conley@witcc.edu

Are you interested in a career in the motorcycle industry? Click here for information on a great technician and parts specialist training program: 
https://www.youtube.com/watch?v=YFWKqGzakiw