Stator Replacement Checklist

[sam000lee]

I'm ordering parts to replace the stator on my '81 GS450L. I'm at school out of state and am planning on going home for a long weekend and trying to bang this out (so that I can maybe ride the bike back). As a consequence of my timeframe I want to make sure I have everything I need the day of. Heres my 'to order' list as well as tentative places I will be buying from.
I don't know how most people feel about ebay but its easy to find things and I've generally had good results in the past.

1. Stator*
2. Side cover gasket: Ricks Gasket
3. Oil filter + oil filter gasket + oil: K&n filter with gasket
4. New stator cover bolts: Something like these

5. And also one of these for good measure: Rick's R/R
6. Impact tool to get old engine screws out: Amazon

*Okay so from what I've gathered (please let me know if I'm wrong). The reason that these stators often go bad is due to the R/R and NOT a faulty stator. Can somebody give me a compelling reason why I should not buy one of these and replace the R/R: Used stator covers with stator.

If the general consensus is against the used one this was my second choice: Caltric

[posplayr]

I'm ordering parts to replace the stator on my '81 GS450L. I'm at school out of state and am planning on going home for a long weekend and trying to bang this out (so that I can maybe ride the bike back). As a consequence of my timeframe I want to make sure I have everything I need the day of. Heres my 'to order' list as well as tentative places I will be buying from.
I don't know how most people feel about ebay but its easy to find things and I've generally had good results in the past.

1. Stator*
2. Side cover gasket: Ricks Gasket
3. Oil filter + oil filter gasket + oil: K&n filter with gasket
4. New stator cover bolts: Something like these

5. And also one of these for good measure: Rick's R/R
6. Impact tool to get old engine screws out: Amazon

*Okay so from what I've gathered (please let me know if I'm wrong). The reason that these stators often go bad is due to the R/R and NOT a faulty stator. Can somebody give me a compelling reason why I should not buy one of these and replace the R/R: Used stator covers with stator.

If the general consensus is against the used one this was my second choice: Caltric

get an SH-775 they are available from Polaris dealers. Do a search several people are sourcing them. It is a SERIES R/R and will avoid future stator issues.

[GreatDane]

Not sure about buying a used Stator...They can be tested (sort of). See Stator Papers. For another 15 bucks you can get the new one.

When I pulled my side cover off to clean it up, I checked my stator. Putting it all back together was no big deal but did take some time. I would probably go with the new stator just to be sure I did not have to do the whole process over again if the used one was bad.

Seems to me that you have everything you need listed above.

Good Luck.

[cowboyup3371]

Get your gaskets from the dealership as the stock ones are better, many of us prefer Boulevard Suzuki as they have very reasonable prices. Also, a Sears impact driver isn't that expensive and has very good bits (or pick up a Harbor Freight one and get the bits at Sears).

[tom203]

Don't buy an ebay stator unless you see close up of windings- lots of these critters have been BBQ'ed and it shows. the Caltric is a better deal at $60

[sam000lee]

Okay I'm going to go with a new stator.

Also from the looks of this, it looks like I need two gaskets for the side cover, #17 and #2 - am I misreading the diagram?

And also this impact tool from Sears.

To sum it up:

1. Stator: $60
2. Side cover gasket: $11
3. Oil filter + gasket: $11
4. Impact tool: $20
5. Cover bolts: ~$20
6. R/R: $60
Total: $182 with R/R $122 without. Overall not bad assuming I don't mess anything up!

[sam000lee]

Top for the which gaskets I need question!

[koolaid_kid]

You need gasket #17, magneto. Gasket #2 goes on the other side for the clutch cover.

[Guest]

ahhhhhh......he's got an entire engine block in between those two gaskets...ahhhhhhhhh

[koolaid_kid]

Yeah, it is a bit deceiving, but perhaps better than hunting around for the other gasket. Six of one, half a dozen of the other.

[BigD_83]

If you have a bit of spare cash and can get a good deal, you may as well order the clutch gasket at the same time and save on future shipping costs...

[850 Combat]

I would throw in a soldering iron and some shrink tube in order to delete the main overheated connectors that hastened along the demise of your original charging system. I would at a minimum, solder the three stator wires, and the r/r OUTPUT WIRE. sorry for the accidental cap lock.

[robertbarr]

... and I could suggest Loctite for the three stator fasteners.

We can all argue & get really belligerent about which Loctite, but I wound up pulling my cover a second time because of nagging doubts. (I think I wound up using Green...).

There was / is a user here who had a stator screw back out on him, and it caused catastrophic damage.

[cowboyup3371]

I had one back out and chip the rotor on mine

[sam000lee]

Okay thanks all - I hadn't thought about the locktite thing. Doing this over thanksgiving weekend I'll let you know how it goes.