2004 Bombardier Outlander 330 How To Remove Stator

[rgeiser]

2004 Bombardier Outlander 330 does anyone know if you have to split cases to get to the stator? Have a costumer who wants a quote but from the parts diagram makes it look like stator is in the cases. is any one familiar with this machine?

[Mech]

There's a service manual in the manuals section of this site.. it will tell you.

[Mech]

The book I have says you have to pull the motor out and take off a side cover.. but it's not the exact model as you are looking at..

[rgeiser]

thats what i was worried about.  ill find manual thanks

 

[rgeiser]

so the ohms between each leg are less than 1. no shorts to ground. each leg is putting out 7vac at idle just above idle 15vac half throttle 25vac 50vac at high revs. sorry cant give exact rpms costumer removed speedo. but only getting 12vdc from reg rec at high rpm. seeing as the motor has to be removed to check stator do yall think its a reg rec?

 

also manual says 10 to 12vac on each leg at idle.

[Mech]

It looks to me like the reg isn't doing it's job properly. With those voltages at the stator it looks like it should be charging. I wouldn't worry too much about the voltage being slightly low at idle.

I'd check the DC output of the reg for any AC, which indicates one failed diode. Then I'd check the earth connection from the reg all the way to the battery, so reg to body, body to battery, and I'd check the charging wire going from the reg to the battery.

[rgeiser]

all 6 diodes seem to be working. less than 0.5vac when hooked to output "red charging wire."  guess I'm gonna let the costumer decide what to do.  really dont want to pull the motor just to look at sator that seems to be working ok

[Mech]

That's what being professional is all about, sometimes we have to make some pragmatic decision, such as this one you have here, and in these situations we need to be able to explain and justify our reasoning, decisions, actions and workmanship...  Which you can..   

Depending on the price, fitting a new regulator is probably the pragmatic thing to do, before pulling the bike to bits possibly for no reason. When we can't be certain, it's better to take the cheapest option first.

You did check for a bad earth on the reg did you ? And the wire from the reg to the battery ?  Either of those could cause the low voltage.. the earth being the most likely..

[rgeiser]

black wire to batt neg 0.5ohms   body of reg rec to batt neg 0.3ohms

talked to owner and he told me he already replaced reg rec and it didn't change anything.  

[Mech]

It's strange that the ohms are good on the stator and they are putting out voltage. I doubt the windings are the problem. A weak magnet from sitting unused perhaps, or metal filings bridging the magnets or bridging the gap between magnets and stator poles ?

I'd have expected both those ohm readings, from the black wire, and the reg's body, to be the same, and probably a little less than a half ohm..  Perhaps try a jumper earth from the black wire and/or reg's body to try it. The reg is regulating, but if it's not earthing properly it will think the voltage is higher than it is by some small amount.. 

If that doesn't make any difference then one last check would be to put a bulb onto the stator wires..  A bulb will work on AC and it will test there is some amperage coming out..

We're on 230 volts here in NZ and I've used a 100 watt household bulb before to test stators.. they glow fairly brightly.

If none of that works then it looks like pulling the motor and having a look is the next step..

[Gooey-T]

From what I read in my manual, it would appear that there are specific tests to be taken IN ORDER to determine if a STATOR needs replacement.  Same thing with the Regulator.  I don't have it at hand, but I was deep into it diagnosing* a starter issue recently - all up and running now! 

If tests to date indicate a bad regulator, accept those results and see about returning the one customer purchased before pulling the engine (BTW there is only one motor on the 330 and it is the starter motor - the device that helps start the engine!).

Look in the SPECS section and the Troubleshooting section to see if you can find the diagnostic checklist. There HAS to be one 'cause CanAm has to be able to fix what they sell! By now (what 20 years on) they should have run into just about everything that might go awry and has.

At least three CANAM dealers however, told me "We don't work on ATVs that old."  One wanted $125 to 'diagnose' the problem when I asked "How much to R&R the starter?"  When I told him I wasn't looking for a second opinion, just a price for the R&R, he (Schronce Powersports, Taylorsville, NC) told me that there likely weren't any starters available!

Best you can hope for is a fellow mechanic with a link to a great repair manual and electrical system checklist.  I would also search Diagnosing electrical issues on" 2004 CAN AM Outlander 330" with two fingers crossed. Just possible that mechanic with the checklist did a video!

I found a list of repair manual files on this page - but have NOT d/l'd anything from it. http://files.brptuning.ru/Bombardier/Manuals/ATV/

Let us know what you discover!

 

[Gwbarm]

Thats crazy, I don't even consider 2004 old, as long as they can still get parts they should work on them 

[Mech]

Ha..  He asked for a remove and overhaul quote, and they started straight off suggesting they would fit a new starter.. if one was available. They didn't want to job.. 

 

And yeah Gooey, we're not so pedantic about motor/engine here in NZ..  Sorry about that.

[Gooey-T]

Correction/update: I did d/l 

 9/17/2013  8:45 PM     35368997 2006_Outlander_400_800_Series_Service_Manual.pdf  from http://files.brptuning.ru/Bombardier/Manuals/ATV/

And, it helped me R&R my 330 starter. So far, my laptop hasn't crashed. 

[Gooey-T]

On 2/7/2023 at 6:11 PM, Mech said:

It's strange that the ohms are good on the stator and they are putting out voltage. I doubt the windings are the problem. A weak magnet from sitting unused perhaps, or metal filings bridging the magnets or bridging the gap between magnets and stator poles ?

I'd have expected both those ohm readings, from the black wire, and the reg's body, to be the same, and probably a little less than a half ohm..  Perhaps try a jumper earth from the black wire and/or reg's body to try it. The reg is regulating, but if it's not earthing properly it will think the voltage is higher than it is by some small amount.. 

If that doesn't make any difference then one last check would be to put a bulb onto the stator wires..  A bulb will work on AC and it will test there is some amperage coming out..

We're on 230 volts here in NZ and I've used a 100 watt household bulb before to test stators.. they glow fairly brightly.

If none of that works then it looks like pulling the motor and having a look is the next step..

On pages 198-200+ in the manual they detail the testing of the stator in situ - no need to pull the thing to test it!

9/17/2013 8:45 PM 35368997 2006_Outlander_400_800_Series_Service_Manual.pdf
from http://files.brptuning.ru/Bombardier/Manuals/ATV/

I would assume that, if teh stator tests AOK, one need look elsewhere for the problem before tearing the 'motor' down to replace it. 

[spock58]

Can Am Outlander 400's had voltage regulators that failed and needed updating. There was a new design that included a different wiring harness I believe. Not sure if this would be the issue here but it should be checked into.

[Gooey-T]

Yep, I ran into that right after I bought a USED 330. Closest CanAM dealer wasted my time and money replacing batteries and such while charging for 'diagnoses and shop materials. I finally went online, found RM STATOR and bought the new version. Basically plug and play - $90US and not an issue since.  I found out much later that 1. there is a simple test a dealer should have known about as well as 2. there were 'factory bulletins on the issue some time before I brought my 330 into Schronce Powersports. So, I like RM Stator!